U.S. patent number RE38,444 [Application Number 09/586,745] was granted by the patent office on 2004-02-24 for absorbing agent, process of manufacturing same, and absorbent product containing same.
This patent grant is currently assigned to Nippon Shokubai Co., Ltd.. Invention is credited to Shin-ichi Fujino, Yoshihiko Masuda, Kinya Nagasuna, Katsuyuki Wada.
United States Patent |
RE38,444 |
Wada , et al. |
February 24, 2004 |
**Please see images for:
( Certificate of Correction ) ** |
Absorbing agent, process of manufacturing same, and absorbent
product containing same
Abstract
An absorbing agent has a diffusing absorbency under pressure of
not less than 25 g/g when 60 minutes elapsed after absorption is
started, and a water-soluble content is above 0 percent by weight
and not more than 7 percent by weight. The absorbing agent is
prepared by surface-crosslinking a precursor of the absorbing agent
obtained by performing an aqueous solution polymerization of a
hydrophilic unsaturated monomer having not less than 50 mole
percent neutralized acrylic acid as a main component using a
specific crosslinking agent having a main component composed of an
ester compound of a specific polyhydroxy alcohol and an unsaturated
carboxylic acid, and a high-boiling component having at least two
alcohol structures in a molecule as a specific ratio. As a result,
an absorbing agent having excellent properties such as the
diffusing absorbency under pressure is high, the water soluble
content is small, and the amount of wet back of the aqueous liquid
after a long period of time is small, water absorbency under
pressure can be stably maintained for a long period of time can be
achieved.
Inventors: |
Wada; Katsuyuki (Himeji,
JP), Nagasuna; Kinya (Nara, JP), Fujino;
Shin-ichi (Himeji, JP), Masuda; Yoshihiko
(Takarazuka, JP) |
Assignee: |
Nippon Shokubai Co., Ltd.
(Osaka, JP)
|
Family
ID: |
31721657 |
Appl.
No.: |
09/586,745 |
Filed: |
June 2, 2000 |
PCT
Filed: |
December 28, 1995 |
PCT No.: |
PCT/JP95/01150 |
PCT
Pub. No.: |
WO95/34377 |
PCT
Pub. Date: |
December 21, 1995 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
571960 |
Dec 28, 1995 |
05760080 |
Jun 2, 1998 |
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Foreign Application Priority Data
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Jun 13, 1994 [JP] |
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6-130385 |
Jun 14, 1994 [JP] |
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6-132126 |
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Current U.S.
Class: |
524/559;
525/328.3; 525/328.5; 525/329.4; 525/329.5; 525/380; 525/382;
525/384 |
Current CPC
Class: |
A61L
15/60 (20130101); C08F 220/06 (20130101) |
Current International
Class: |
A61L
15/60 (20060101); A61L 15/16 (20060101); C08F
220/06 (20060101); C08F 220/00 (20060101); C08F
008/32 (); C08F 008/14 () |
Field of
Search: |
;524/559
;525/328.3,328.5,329.4,329.5,380,382,384 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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40 20 780 |
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Aug 1991 |
|
DE |
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0 530 438 |
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Mar 1993 |
|
EP |
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0 532 002 |
|
Mar 1993 |
|
EP |
|
0 555 692 |
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Aug 1993 |
|
EP |
|
0 304 319 |
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Feb 1994 |
|
EP |
|
49-43395 |
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Nov 1974 |
|
JP |
|
51-125468 |
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Jan 1976 |
|
JP |
|
52-14689 |
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Mar 1977 |
|
JP |
|
53-15959 |
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May 1978 |
|
JP |
|
55-84304 |
|
Jun 1980 |
|
JP |
|
55-108407 |
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Aug 1980 |
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JP |
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55-133413 |
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Oct 1980 |
|
JP |
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58-154709 |
|
Sep 1983 |
|
JP |
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58-154710 |
|
Sep 1983 |
|
JP |
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63-21902 |
|
Jan 1988 |
|
JP |
|
63-99861 |
|
May 1988 |
|
JP |
|
63-275608 |
|
Nov 1988 |
|
JP |
|
1-292004 |
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Nov 1989 |
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JP |
|
2-34167 |
|
Feb 1990 |
|
JP |
|
2-242809 |
|
Sep 1990 |
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JP |
|
3-56513 |
|
Mar 1992 |
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JP |
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WO 94/09043 |
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Apr 1994 |
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WO |
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Primary Examiner: Lipman; Bernard
Attorney, Agent or Firm: Kubovcik & Kubovcik
Claims
What is claimed is:
1. An absorbing agent formed from a precursor prepared by
.[.performing an aqueous solution.]. polymerization of a
hydrophilic unsaturated monomer having .[.at least 50 mole percent
neutralized.]. .Iadd.an .Iaddend.acrylic acid .Iadd.and/or an
acrylic acid salt .Iaddend.as a main component, and having a
crosslinked density in the vicinity of a surface of said agent
higher than a crosslinked density at an inside portion thereof,
said absorbing agent having a diffusing absorbency under pressure
of not less than .[.25.]. .Iadd.30 .Iaddend.g/g when 60 minutes
have elapsed after absorption has started.
2. .[.An.]. .Iadd.The .Iaddend.absorbing agent .[.formed from a
precursor prepared by performing an aqueous solution polymerization
of a hydrophilic unsaturated monomer having at least 50 mole
percent neutralized acrylic acid as a main component, and having a
crosslinked density in the vicinity of a surface of said agent
higher than a crosslinked density at an inside portion thereof,
said absorbing agent having.]. .Iadd.as set forth in claim 1,
wherein .Iaddend. a diffusing absorbency under pressure .[.of.]. is
not less than .[.15.]. .Iadd.32 .Iaddend.g/g when .[.30.]. .Iadd.60
.Iaddend.minutes have elapsed after absorption has started.
3. The absorbing agent as set forth in claim .[.2.].
.Iadd.1.Iaddend., wherein: a diffusing absorbency under pressure is
not less than .[.25.]. .Iadd.34 .Iaddend.g/g when 60 minutes
.Iadd.have .Iaddend.elapsed after absorption has started.
4. .[.An.]. .Iadd.The .Iaddend.absorbing agent .[.formed from a
precursor prepared by performing an aqueous solution polymerization
of a hydrophilic unsaturated monomer having at least 50 mole
percent neutralized acrylic acid as a main component, and having a
crosslinked density in the vicinity of a surface of said agent
higher than a crosslinked density at an inside portion thereof,
said absorbing agent having.]. .Iadd.as set forth in claim 1,
wherein .Iaddend. a diffusing absorbency under pressure .[.of.].
.Iadd.is .Iaddend.not less than 15 g/g when .[.20.]. .Iadd.30
.Iaddend.minutes have elapsed after absorption has started.
5. The absorbing agent as set forth in claim .[.4.].
.Iadd.1.Iaddend., wherein: a diffusing absorbency under pressure is
not less than .[.25.]. .Iadd.15 .Iaddend.g/g when .[.60.]. .Iadd.20
.Iaddend.minutes .Iadd.have .Iaddend.elapsed after absorption has
started. .[.
6. The absorbing agent as set forth in claim 4, wherein: a
diffusing absorbency under pressure is not less than 30 g/g when 60
minutes elapsed after absorption has started..].
7. The absorbing agent as set forth in claim 1, wherein: a water
soluble component amount is above 0 and not more than 7 percent by
weight.
8. The absorbing agent as set forth in claim 1, containing a
dispersant.
9. The absorbing agent as set forth in claim 8, wherein: said
dispersant is contained in an amount in a range of 0.005 parts by
weight to 0.5 parts by weight with respect to 100 parts by weight
of .[.a.]. .Iadd.the .Iaddend.precursor of the absorbing
agent.Iadd., composed of a monomer.Iaddend..
10. An absorbent material, comprising: .Iadd.an absorbing agent in
an amount of .Iaddend.not less than 40 percent by weight .[.of an
absorbing agent formed from a precursor prepared by performing an
aqueous solution polymerization of a hydrophilic unsaturated
monomer having at least 50 mole percent neutralized acrylic acid as
a main component, and having a cross-linked density in the vicinity
of a surface of said agent higher than a crosslinked density at an
inside portion thereof.]. , said absorbing agent having a diffusing
absorbency under pressure of .[.25.]. .Iadd.not less than 30
.Iaddend.g/g when 60 minutes have elapsed after absorption has
started.
11. The absorbent material as set forth in claim 10, wherein:
.Iadd.said absorbing agent has .Iaddend.a diffusing absorbency
under pressure .[.is.]. .Iadd.of .Iaddend.not less than .[.15.].
.Iadd.32 .Iaddend.g/g when .[.30.]. .Iadd.60 .Iaddend.minutes
.Iadd.have .Iaddend.elapsed after absorption has started.
12. The absorbent material as set forth in claim 10, further
comprising: a hydrophilic fiber.
13. The absorbent material as set forth in claim 12, wherein: said
hydrophilic fiber is contained in an amount in a range of above 0
percent by weight and not more than 60 percent by weight.
14. The absorbent material as set forth in claim 12, wherein: said
absorbing agent is contained in an amount of not less than 50
percent by weight with respect to a total amount of said absorbing
agent and said hydrophilic fiber.
15. The absorbent material as set forth in claim 10, further
comprising: an adhesive binder.
16. An absorbent product, comprising: an absorbent material
including an absorbing agent .[.formed from a precursor prepared by
performing an aqueous solution polymerization of a hydrophilic
unsaturated monomer having at least 50 mole percent neutralized
acrylic acid as a main component, and having a cross-linked density
in the vicinity of a surface of said agent higher than a
crosslinked density at an inside portion thereof, said absorbing
agent.]. having a diffusing absorbency under pressure of not less
than .[.25.]. .Iadd.30 .Iaddend.g/g when 60 minutes have elapsed
after absorption has started, and a water soluble .[.content in a
range of greater than.]. .Iadd.component amount of above .Iaddend.0
.[.percent by weight.]. and not more than 7 percent by weight.
17. The absorbent product as set forth in claim 16, wherein: said
.[.absorbent material.]. .Iadd.absorbing agent further
.Iaddend.contains a hydrophilic fiber in an amount in a range of
above 0 percent by weight and not more than 60 percent by weight
.Iadd.with respect to said absorbing agent.Iaddend..
18. The absorbent product as set forth in claim 17, wherein:
.[.said absorbent material includes.]. said hydrophilic fiber
.Iadd.is contained .Iaddend.in an amount in a range .[.between.].
20 percent by weight .[.and.]. .Iadd.to .Iaddend.40 percent by
weight .Iadd.with respect to said absorbing agent.Iaddend..
19. The absorbent product as set forth in claim 16, wherein: said
absorbent material further .[.includes.]. .Iadd.contains
.Iaddend.an adhesive binder.
20. An absorbent product comprising: an absorbing layer .[.of claim
1 including an absorbent material being.]. sandwiched between a
sheet which is permeable to liquid and a sheet which is impermeable
to liquid.Iadd., said absorbing layer containing an absorbing agent
having a diffusing absorbency under pressure of not less than 30
g/g when 60 minutes have elapsed after absorption has
started.Iaddend..
21. A process of manufacturing an absorbing agent, comprising the
steps of: performing an aqueous solution polymerization of a
hydrophilic unsaturated monomer having at least 50 mole percent
neutralized acrylic acid as a main component in a presence of a
dispersant .Iadd.to prepare a precursor of said absorbing
agent.Iaddend., using a crosslinking agent composed of a main
component and a high-boiling point component in a range of not less
than 0.05 mole percent and not more than 0.5 mole percent with
respect to a total amount of said hydrophilic unsaturated monomer,
wherein a ratio in weight of the main component of said
crosslinking agent to said high-boiling point component is in a
range of 75/25 to 99/1, said main component of said crosslinking
agent is composed of an ester compound including a
.[.polyhydroxy.]. .Iadd.polyvalent .Iaddend.alcohol having not more
than six carbon atoms and at least three hydroxy groups and an
unsaturated carboxylic acid, a ratio in molecular weight of the
main component of said crosslinking agent to .[.the.]. .Iadd.a
.Iaddend.standard compound is in a range of not less than 0.7 and
less than 1.3 based on .[.a.]. .Iadd.the .Iaddend.molecular weight
of .[.a.]. .Iadd.the .Iaddend.standard compound wherein all hydroxy
group of the polyvalent alcohol are ester-linked to the unsaturated
carboxylic acid, and said high-boiling point component includes at
least two alcohol structures in a molecule; adjusting said
precursor of said absorbing agent so as to have a water content of
not more than 10 percent, an average particle diameter in a range
of 200 .mu.m-600 .mu.m, and a ratio of particles having a diameter
of not more than 106 .mu.m of not more than 10 percent by weight;
and applying a heat treatment to said precursor of said absorbing
agent in a presence of a surface crosslinking agent.
22. The process of manufacturing the absorbing agent as set forth
in claim 21, wherein: said surface crosslinking agent is composed
of a first surface crosslinking agent reactive to a carboxyl group
having a solubility parameter (SP value) of not less than 12.5
(cal/cm.sup.3).sup.1/2 and a second surface crosslinking agent
having a solubility parameter of less than 12.5
(cal/cm.sup.3).sup.1/2 ; and the heat treatment is performed at
.Iadd.a .Iaddend.temperature of not less than 160.degree. C.
.Iadd.
23. The absorbent material as set forth in claim 10, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 34 g/g when 60 minutes have elapsed after absorption has
started..Iaddend..Iadd.
24. The absorbent material as set forth in claim 10, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 15 g/g when 30 minutes have elapsed after absorption has
started..Iaddend..Iadd.
25. The absorbent material as set forth in claim 10, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 15 g/g when 20 minutes have elapsed after absorption has
started..Iaddend..Iadd.
26. The absorbent material as set forth in claim 16, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 32 g/g when 60 minutes have elapsed after absorption has
started..Iaddend..Iadd.
27. The absorbent material as set forth in claim 16, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 34 g/g when 60 minutes have elapsed after absorption has
started..Iaddend..Iadd.
28. The absorbent material as set forth in claim 16, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 15 g/g when 30 minutes have elapsed after absorption has
started..Iaddend..Iadd.
29. The absorbent material as set forth in claim 16, wherein: said
absorbing agent has a diffusing absorbency under pressure of not
less than 15 g/g when 20 minutes have elapsed after absorption has
started..Iaddend..Iadd.
30. The absorbing agent as set forth in claim 1, said agent is
prepared by applying a heat treatment to a precursor having an
internal crosslinking structure in the presence of a first surface
crosslinking agent having a solubility parameter (SP value) of not
less than 12.5(cal/cm.sup.3).sup.1/2 and a second surface
crosslinking agent having a solubility parameter of less than
12.5(cal/cm.sup.3).sup.1/2..Iaddend.
Description
FIELD OF THE INVENTION
The present invention relates to an absorbing agent suited for use
in sanitary goods such as paper diaper (disposable diaper),
sanitary napkin, incontinence pad, etc., and a method of
manufacturing the same and also relates to an absorbent product
containing such absorbing agent.
BACKGROUND OF THE INVENTION
Recently, an absorbent resin is widely used in sanitary goods such
as paper diaper, sanitary napkin, incontinence pad, etc., for the
purpose of absorbing liquid.
Examples of known absorbent resins include: a partially neutralized
crosslinked polymer of polyacrylic acid (Japanese Laid-Open Patent
Publication No. 84304/1980 (Tokukaisho 55-84304), Japanese
Laid-Open Patent Publication No. 108407/1980 (Tokukaisho 55-108407)
and Japanese Laid-Open Patent Publication No. 133413/1980
(Tokukaisho 55-133413)); a hydrolyzed graft polymer of
starch-acrylonitrile (Japanese Examined Patent Publication No.
43995/1974 (Tokukosho 46-43995)); a neutralized graft polymer of
starch-acrylic acid (Japanese Laid-Open Patent Publication No.
125468/1976 (Tokukaisho 51-125468)); a saponified copolymer of
vinyl acetate-acrylic ester (Japanese Laid-Open Patent Publication
No. 14689/1977 (Tokukaisho 52-14689)); a hydrolyzed copolymer of
acrylonitrile or of acrylamide (Japanese Examined Patent
Publication No. 15959/1978 (Tokukosho 53-15959)); a crosslinked
polymer of cationic monomer (Japanese Laid-Open Patent Publication
No. 154709/1983 (Tokukaisho 58-154709) and Japanese Laid-Open
Patent Publication No. 154710/1983 (Tokukaisho 58-154710)).
Notable properties of the absorbent resin include absorbing
capacity and absorbency under pressure when it is in contact with
an aqueous liquid like a body fluid, gel strength, and absorbing
power of absorbing liquid from a base material containing an
aqueous liquid, etc. Conventionally, the absorbent resins having
some of the above-mentioned properties which show desirable
properties (absorption properties) in their applications of paper
diaper, sanitary napkin, etc., as well as absorbent materials and
the absorbent product using such absorbent resins have been
proposed.
Examples of such absorbent resins, absorbent materials and
absorbent products include: an absorbent resin disclosing a
combination of a specific gel capacity, shear modulus and an
extraction polymer content (U.S. Pat. No. 4,654,039); an absorbent
resin having predetermined ranges of absorbing capacity and
absorbency under pressure and gel stability, and a paper diaper and
a sanitary napkin using such absorbent resin (Japanese Laid-Open
Patent Publication No. 185550/1985 (Tokukaisho 60-185550)),
(Japanese Laid-Open Patent Publication No. 185551/1985 (Tokukaisho
60-185551)) and (Japanese Laid-Open Patent Publication No.
185804/1985 (Tokukaisho 60-185804)); a paper diaper using an
absorbent resin having predetermined ranges of absorbing capacity,
absorbency under pressure and a gel stability (Japanese Laid-Open
Patent Publication No. 185805/1985 (Tokukaisho 60-185805)); an
absorbent product having predetermined absorbing capacity,
absorbing power and water soluble content (Japanese Laid-Open
Patent Publication No. 21902/1988 (Tokukaisho 63-21902)); an
absorbent sanitary product including an absorbent resin having
predetermined ranges of absorbing capacity, absorbing capacity
under pressure, and a gel breaking strength (Japanese Laid-Open
Patent Publication No. 99861/1988 (Tokukaisho 63-99861)); a paper
diaper including an absorbent resin having predetermined ranges of
absorbing capacity and absorbency under pressure (Japanese
Laid-Open Patent Publication No. 34167/1990 (Tokukaihei 2-34167));
an absorbing agent containing an absorbent resin having
predetermined ranges of absorbing capacity under pressure and
particle diameter (European Patent No. 339,461); an absorbing agent
including at least a predetermined amount of an absorbent resin
having predetermined ranges of absorbency under pressure and
absorbing capacity under pressure in a short period of time
(European Patent No. 443,627); an absorbing synthetic material
having at least predetermined amount of absorbent resin having
predetermined ranges of deformation and absorbing index when
applying a load (European Patent No. 532,002).
Recently, still thinner sanitary goods such as a paper diaper and a
sanitary napkin of higher quality have been demanded, and an amount
of use of the absorbent resin or weight percent of the absorbent
resin in the absorbent material mainly composed of absorbent resin
and hydrophilic fiber (hereinafter simply referred to as a resin
concentration) has been increasing. Namely, by reducing the amount
of hydrophilic fiber having a small bulk specific gravity and
increasing the amount of the absorbent resin having a large bulk
specific gravity, the ratio of the absorbent resin in the absorbent
material is raised, and a thinner sanitary material can be achieved
without reducing the absorbing capacity.
However, earnest researches have been made by the inventors of the
present invention in order to increase the absorbing amount of the
sanitary material, for example, by increasing the resin
concentration in the absorbent material. As a result, the inventors
have found that the absorbent material having a higher resin
concentration than conventional absorbent material cannot be used
without having problems such as leakage of aqueous liquid from the
sanitary goods, etc., only by controlling the described absorbing
capacity, absorbency under pressure, gel strength, absorbing
capacity, etc. For example, as to the absorbent resin which has
been viewed with interest in which only absorbing capacity under
pressure is large, by raising the resin concentration, the liquid
dispersability of the absorbent material is significantly
reduced.
Further researches have been made by the inventors on absorbing
properties of the absorbent material having higher resin
concentration than conventional absorbent material. As a result,
they have found that in the case of using a mixture of a known
absorbent resin, a hydrophilic fiber is used as an absorbent
material, although when a resin concentration is low, the absorbent
material shows a predetermined level of absorbing properties, when
a resin concentration is above 40 percent by weight, such
unpreferable conditions that the liquid dispersibility is rapidly
lowered, the absorbing capacity of weight per unit of the absorbent
material is lowered, the water absorbing capacity cannot be ensured
for a long period of time; an amount of wet back of the aqueous
liquid increases, etc., would occur. Namely, when a mixture of the
known absorbent resin and the hydrophilic fiber is used as an
absorbent material, the above-mentioned problems would arise.
Accordingly, an object of the present invention is to eliminate the
above-mentioned problems and to provide an absorbing agent having
excellent properties (absorbing properties) such as very high
liquid diffusivity and a stability over time of the absorbing
capacity irrespectively of the resin concentration or the structure
of the absorbent material, for example, when it is used as sanitary
goods, etc., as well as a process of manufacturing such absorbing
agent and the absorbent product including the absorbing agent.
Another object of the present invention is to provide an absorbing
agent having excellent properties (absorbing properties, etc.,) of
maintaining very high liquid diffusivity and absorbing capacity
even with high resin concentration.
[Disclosures of the Invention]
In order to achieve the above object, earnest researches on the
absorbing agent and the manufacturing method thereof have been made
by inventors of the present invention. As a result, an absorbing
agent obtained by synthesizing the precursor of the absorbing agent
by performing an aqueous solution polymerization of the hydrophilic
unsaturated monomer having more than 50 mole percent neutralized
acrylic acid as a main component in the presence of the
crosslinking agent and dispersant, and applying a heat treatment in
a presence of a surface crosslinking agent after adjusting the
precursor of the absorbing agent so as to have a predetermined
range of water content and a predetermined range of the particle
diameter, exhibit excellent properties such as very high liquid
diffusivity and stable absorbing capacity over time. Namely, the
absorbing agent obtained by synthesizing the precursor of the
absorbing agent and applying the heat treatment in a presence of a
specific surface crosslinking agent, the absorbent material and the
absorbent product including such absorbing agent exhibit excellent
performances such as very high liquid diffusivity, absorbing
capacity, etc., even when the amount of use of the absorbent resin
and the resin concentration are high.
Namely, in order to solve the above-mentioned problem, an absorbing
agent of the present invention is characterized in that the
diffusing absorbency under pressure measured when 60 minutes has
elapsed after an absorption is started is 25 g/g.
In order to solve the above-mentioned problem, the absorbent
material of the present invention may be characterized by including
not less than 40 percent by weight of the absorbing agent.
In order to solve the above-mentioned problem, the absorbent
material of the present invention may be characterized in that its
diffusing absorbency under pressure measured when 60 minutes has
elapsed after the absorption is started is not less than 25 g/g,
and the water soluble content is above 0, and the absorbing agent
is not more than 7 percent by weight.
The following will explain the present invention in details.
The diffusing absorbency under pressure in the present invention
suggests a new property value for evaluating the absorbency under
pressure of the absorbing agent and the absorbent material in view
of the diffusivity of the aqueous liquid wherein the weighing
capacity of the absorbent resin is high and resin particles are
tightly linked one another by an external force.
The diffusing absorbency under pressure is computed based on values
measured when a predetermined time elapsed after the absorption is
started under predetermined conditions, for example, after 20
minutes, 30 minutes, and 60 minutes, etc. The method of measuring
the diffusing absorbency under pressure will be explained in
below-mentioned embodiments.
The diffusing absorbency under pressure enables evaluations of new
properties of the absorbing agent, the absorbent material, i.e.,
the absorbent resin. Namely, the diffusing absorbency under
pressure evaluates the uniformity and the diffusivity of the
absorbent resin in the aqueous liquid in a resin layer direction
(hereinafter simply referred to as a lateral direction), or an
actual absorbing capacity of the absorbent resin as a whole. The
liquid diffusivity in a lateral direction (liquid diffusivity and
liquid transmissivity) is an important factor of absorbing a large
amount of aqueous liquid. Based on the results of evaluation, for
example, the absorbing ability of the absorbent material mainly
composed of the absorbing agent (absorbent resin) and hydrophilic
fiber can be easily estimated especially in the absorbent resin in
the absorbent material having high percent by weight (hereinafter
referred to as a resin concentration) of the absorbent resin. The
configuration of the absorbent material will be explained
later.
Many prior art applications disclose evaluations of the absorbing
capacity under pressure. However, in conventional methods, the
absorbing capacity is evaluated only in the direction orthogonal to
the resin layer direction (hereinafter simply referred to as a
longitudinal direction). Therefore, in this method, the uniformity
and the diffusivity of the aqueous liquid are hardly known.
Therefore, from the conventional evaluation results, the absorbing
capacity of the absorbent material in a paper diaper, etc.,
adopting the absorbent material having a high resin concentration
cannot be estimated accurately.
The water soluble content in the present invention suggests
property values for evaluating the rediffusivity of the aqueous
liquid after a long time elapsed when the absorbent resin has
excellent diffusing absorbency under pressure and evaluating the
ability of maintaining absorbed aqueous liquid for a long period of
time. The described water soluble content is measured under
predetermined conditions. The method of measuring the water soluble
content will be described in detail in the below-mentioned
embodiments.
Even if the absorbent resin has excellent diffusing absorbency
under pressure, if the water soluble content thereof is outside the
predetermined range of the present invention, the amount of wet
back of the aqueous liquid after a long period of time elapsed
tends to increase. On the other hand, the absorbing agent, i.e.,
the absorbent resin of the present invention satisfies both the
diffusing absorbency under pressure and the water soluble content.
The absorbing agent having excellent properties such as very high
liquid diffusivity and stable absorbing capacity for a long period
of time without being much affected by the configuration of the
resin concentration or the absorbent material, etc., the process of
manufacturing thereof and the absorbent product including such
absorbing agent will be explained.
The absorbing agent of the present invention has the diffusing
absorbency under pressure of not less than 25 g/g and the water
soluble content of not more than 7 percent by weight. In the
absorbing agent, i.e., the absorbent resin having the diffusing
absorbency under pressure of less than 25 g/g, i.e., the absorbent
resin, the liquid diffusivity in the lateral direction in the
absorbent material (high concentration) with an increased resin
concentration is deteriorated, and the absorbing capacity of the
absorbent material is lowered. In the present invention, it is
preferable that the diffusing absorbency under pressure is not less
than 28 g/g, more preferably not less than 30 g/g, and most
preferably not less than 32 g/g. Even if the absorbent resin has
the diffusing absorbency under pressure of not less than 25 g/g, if
the water soluble content is above 7 percent by weight, the amount
of wet back of the aqueous liquid after a long time elapsed would
increase. It is preferable that the water soluble content is not
more than 5 percent by weight, and more preferably not more than 3
percent by weight. In the present invention, the diffusing
absorbency under pressure is determined by values measured when 60
minutes has elapsed after the absorption is started under
predetermined conditions. In addition, the absorbing agent having
the diffusing absorbency under pressure of not less than 15 g/g
computed from the value measured when 20 minutes has elapsed after
the absorption is started is preferable, and those having the
diffusing absorbency under pressure of not less than 20 g/g is more
preferable.
The absorbent product of the present invention is characterized by
including the absorbing agent having the described excellent
properties as the absorbent material. However, other than the
absorbing agent, such absorbent material may include hydrophilic
fiber when an occasion demands. Examples of the structures of the
absorbent material in the case where the absorbent material
composed of, for example, the absorbing agent and a hydrophilic
fiber include: the structure wherein an absorbing agent and a
hydrophilic fiber are uniformly mixed; a structure wherein the
absorbing agent is sandwiched between layered hydrophilic fiber; a
structure wherein the absorbing agent and the hydrophilic fiber are
homogeneously mixed so as to form a layer and a hydrophilic fiber
is formed thereon; the structure wherein the absorbing agent is
sandwiched between the layered hydrophilic fiber and the layer
formed of mixing uniformly the absorbing agent and the hydrophilic
fiber. Furthermore, the absorbent material is obtained by forming
the absorbing agent in a sheet by mixing a predetermined amount of
water with respect to the absorbing agent. In addition, the
structure of the absorbent material is not limited to the
exemplified structure.
Examples of the hydrophilic fiber include: a cellulose fiber such
as a mechanical pulp, a chemical pulp, a semi-chemical pulp, a
dissolved pulp, etc.; an artificial cellulose fiber such as rayon,
acetate, and the like. Among the above-listed fiber, cellulose
fiber is preferable. The hydrophilic fiber may include a synthetic
fiber such as polyamide, polyester, polyolefin, etc. The
hydrophilic fiber of the present invention is not limited to the
above-listed fibers.
To obtain excellent properties, the absorbing agent of the present
invention is characterized in that it is preferable that the ratio
of the hydrophilic fiber in the absorbent material is above 0, and
not more than 60 percent by weight, more preferably not less than
20 percent by weight and not more than 40 percent by weight. The
higher is the resin concentration of the absorbent material, the
more obvious are the properties of the absorbing agent and the
absorbent material. The performances of the absorbent resin of the
present invention can be fully exhibited irrespectively of the
ratio of the hydrophilic fiber in the absorbent material. In
addition, the performances of the absorbing agent are hardly
affected by the described configuration of the absorbent
material.
When the ratio of the hydrophilic fiber in the absorbent material
is relatively small, the absorbent material, namely the hydrophilic
fibers may be linked by using an adhesive binder. By linking the
hydrophilic fiber, the strength and the shape retention before and
while using the absorbent material can be high.
Examples of such adhesive binder include: thermal fusing fiber such
as polyethylene, polypropylene, ethylene-propylene copolymer,
1-butene-ethylene copolymer, and the like, emulsion having an
adhesive property, etc. Only one kind of the above-listed adhesive
binder may be adopted, or two or more kinds thereof may be suitably
mixed and adopted. The ratio by weight of the hydrophilic fiber to
the adhesive binder is preferably in a range of 50/50-99/1, more
preferably in a range of 70/30-95/5, still more preferably in a
range of 80/20-95/5.
The absorbing agent in accordance with the present invention is
produced in the following manner. First, a precursor of the
absorbing agent is prepared by performing an aqueous solution
polymerization of hydrophilic unsaturated monomer having at least
50 mole percent neutralized acrylic acid as a main component in a
presence of a crosslinking agent and a dispersant using a certain
amount of the crosslinking agent having a specific composition.
Then, the precursor of the absorbing agent is adjusted so as to
have a specific range of water content and a particle diameter of a
specific range. Thereafter, a heat treatment is applied to the
precursor of the absorbing agent in the presence of the surface
crosslinking agent.
The hydrophilic unsaturated monomer used as a raw material of the
present invention includes acrylic acid and a neutralized material
thereof as a main component. To improve the water absorbing
properties of the water-absorbing agent, it is preferable that at
least 50 mole percent is neutralized by alkali metal salt, ammonium
salt, amine salt, etc. Furthermore, to still improve the absorbing
properties of the absorbing agent, it is still preferable that
around 65 mole percent to 80 mole percent of the acrylic acid is
neutralized.
The hydrophilic unsaturated monomer may include an unsaturated
monomer other than acrylic acid. Such unsaturated monomer other
than acrylic acid is not especially limited. However, such examples
include: an anionic unsaturated monomer such as methacrylic acid,
maleic acid, vinylsulfonic acid, styrenesulfonic acid, 2-(meth)
acrylamide-2-methylpropanesulfonic acid, 2-(meth)
acryloylethanesulfonic acid, 2-(meth) acryloylpropanesulfonic acid,
etc., and salts thereof; a nonionic unsaturated monomer including
hydrophilic groups such as acrylamide, methacrylamide,
N-ethyl(meth) acrylamide, N-n-propyl(meth)acrylamide, N-isopropyl
(meth)acrylamide, N,N-dimethyl(meth)acrylamide,
2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl (meth) acrylate,
methoxypolyethylene glycol (meth)acrylate, polyethylene glycol
mono(meth)acrylate, vinylpyridine, N-vinylpyrrolidone,
N-acryloylpiperidine, N-acryloylpyrrolidine and the like; a
cationic unsaturated monomer such as N,N-dimethyl
aminoethyl(meth)acrylate, N,N-diethyl aminoethyl(meth)acrylate,
N,N-dimethyl aminopropyl(meth)acrylate, N,N-dimethyl aminopropyl
(meth)acrylamide and quaternary salts thereof and the like.
The above-mentioned additional hydrophilic unsaturated monomer is
preferably used in an amount not more than 50 percent by weight
with respect to the total amount of the acrylic acid and the
neutralized product thereof used as a main component.
The crosslinking agent of the present invention is obtained by the
esterification reaction of polyhydroxy alcohol having not more than
six carbon atoms and at least three hydroxy groups (hereinafter
referred to as a polyhydroxy alcohol) and an unsaturated carboxylic
acid among unsaturated carboxylates such as acrylate having plural
functional groups (hereinafter referred to as polyfunctional); or
an transesterification of polyhydroxy alcohol having at least three
hydroxy groups and a unsaturated carboxylic ester. However, it is
difficult to industrially produce the unsaturated carboxylic ester
wherein all the hydroxyl groups of polyhydroxy alcohol having at
least three hydroxy groups and the unsaturated carboxylic acid are
ester exchanged, i.e., a desired unsaturated carboxylic ester at
high selectivity and high yield at low cost. Depending on reaction
conditions, normally, when synthesizing the unsaturated carboxylic
ester, in addition to the desired unsaturated carboxylic ester, a
large amount of a high boiling-point compound having at least two
polyhydroxy alcohol structures in a molecule is generated.
Inventors of the present invention made earnest researches to
achieve the absorbent resin of improved performances prepared by
performing an aqueous solution polymerization of hydrophilic
unsaturated monomer using industrially available unsaturated
carboxylic ester, i.e., unsaturated carboxylic ester including such
high-boiling point compound as a crosslinking agent. As a result,
they have found that when performing a polymerization reaction of
unsaturated carboxylate containing the high-boiling point compound,
it is difficult to improve the diffusing absorbency under pressure
of the absorbing agent and to decrease the amount of water-soluble
component. Thus, further researches have been made by the inventors
to obtain the absorbent resin (i.e., the absorbing agent) which
shows excellent properties including diffusing absorbency under
pressure and liquid diffusivity, etc., and contains smaller amount
of water soluble content. As a result, only when the crosslinking
agent adjusted so as to have a predetermined range of the
high-boiling point component is used in a specific amount in the
presence of the dispersant, the absorbing agent having a small
amount of the water-soluble content and improved absorbency under
pressure, etc., can be achieved.
Namely, the crosslinking agent of the present invention is composed
of an ester compound of a polyhydroxy alcohol having not more than
six carbon atoms and at least three hydroxy groups and an
unsaturated carboxylic acid, wherein a ratio in molecular weight of
the compound to a standard compound in which all the hydroxy groups
in polyhydroxy alcohol having at least three hydroxy groups are
ester-linked to the unsaturated carboxylic acid is in the range of
from 0.7/1 to less than 1.3/1, and a high-boiling point component
having at least two alcohol structures, and a weight ratio of the
main component of the crosslinking agent to the high boiling point
component in a range of 75/25-99/1.
The alcohol having at least three hydroxy groups used in preparing
the crosslinking agent is not specified. However, preferable
examples of the alcohols include: glycerin, trimethylolethane,
tetramethylolethane, trimethylolpropane, tetrahydroxyethane,
pentaerythritol, etc. Among the above listed alcohols,
trimethylolpropane is especially preferable. For the unsaturated
carboxylic acid used in the preparation of the crosslinking agent,
any of the previously listed hydrophilic unsaturated monomers
having at least one carboxyl group may be used. However, acrylic
acid is especially preferable.
As described, the main component of the crosslinking agent may be a
compound in which a ratio in molecular weight of the compound to a
standard compound wherein all the hydroxyl groups of the
polyhydroxy alcohol having at least three hydroxy groups are
ester-linked to the unsaturated carboxylic acid among
multifunctional unsaturated carboxylates which include polyhydroxy
alcohol having at least three hydroxy groups as a alcohol component
and an unsaturated carboxylic acid as an acid component is in a
range between 0.7 to less than 1.3.
For example, in the case where the trimethylolpropane is used as a
polyhydroxy alcohol having at least three hydroxy groups and
acrylic acid is used as an unsaturated carboxylic acid, examples of
the main component of the crosslinking agent include:
trimethylolpropane triacrylate; trimethylolpropane diacrylate;
trimethylolpropane diacrylatemono (.beta.-acryloyloxypropionate),
and the like. In the case where glycerin is used as polyhydroxy
alcohol having at least three hydroxy groups, and acrylic acid is
used as unsaturated carboxylic acid as the main component of the
crosslinking agent, examples of the main component of the
crosslinking agent include: glycerintriacrylate,
glycerinditriacrylate, etc. In the case where trimethylolethane is
used as polyhydroxy alcohol having at least three hydroxy groups,
and acrylic acid is used as unsaturated carboxylic acid as the main
component of the crosslinking agent, examples of the main component
of the crosslinking agent include: trimethylolethanetriacrylate,
trimethylolethane diacrylate, and the like. In the case where the
tetramethylolethane is used as polyhydroxy alcohol having at least
three hydroxy groups and acrylic acid is used as unsaturated
carboxylic acid, examples of the main component of the crosslinking
agent include: tetramethylol ethane tetracrylate,
tetramethylolethane triacrylate, etc. In the case where
tetrahydroxyethane is used as polyhydroxy alcohol having at least
three hydroxy groups and acrylic acid is used as an unsaturated
carboxylic acid, examples of the main component of the present
invention include tetrahydroxyethane tetracrylate, tetrahydroxy
ethane triacrylate, and the like. In the case where pentaerythritol
is used as polyhydroxy alcohol having at least three hydroxy groups
and acrylic acid as unsaturated carboxylic acid, penthaerythritol
tetracrylate, pentaerythritol triacrylate, etc., may be used.
The high-boiling point compound included in the crosslinking agent
having a complicated structure is a by-product generated when
synthesizing the main component of the crosslinking agent. For
example, in the case where the trimethylolpropane is used as the
polyhydroxy alcohol having at least three hydroxy groups and
acrylic acid is used as an unsaturated carboxylic acid, examples of
the high-boiling point component include: condensation products
having at least two trimethylol propane structures in a molecule
such as a compound generated from an additional reaction of
trimethylolpropane triacrylate and trimethylolpropane diacrylate, a
dimer of trimethylolpropane diacrylate, a compound generated by an
additional reaction between trimethylolpropane diacrylate and
trimethylolpropane monoacrylate, etc.
In the present invention, it is necessary to satisfy the condition
that the weight ratio of the crosslinking agent main component and
the high boiling point component in the crosslinking agent is in a
range of 75/25-99/1, and preferably in a range of 80/20-90/10. When
the weight ratio of the main component of the crosslinking agent to
the high boiling point component in the crosslinking agent is less
than 75/25, i.e., when the ratio of the main component of the
crosslinking agent to the total amount of the crosslinking agent
main component and the high boiling point component is less than 75
percent by weight (i.e., when the ratio of the high boiling point
is above 25 percent by weight), even when the dispersant of the
present invention is used, an absorbing agent which shows excellent
diffusing absorbency under pressure and the liquid diffusivity and
the absorbing agent having a smaller amount of water soluble
content cannot be achieved. On the other hand, it is difficult to
obtain a crosslinking agent in which the ratio in weight of the
crosslinking agent main component and the high boiling component is
above 99/1, i.e., the crosslinking agent in which the ratio of the
main component with respect to the total amount of the main
component of the crosslinking agent and the high boiling point
component is above 99 percent by weight (i.e., the ratio of the
high-boiling point component is less than 1 percent by weight) is
not easily obtainable. Therefore, it is not industrially
preferable. In addition, even when using the crosslinking agent
having the main component ratio of the crosslinking agent of above
99 percent by weight, compared to the case of using the
crosslinking agent in an amount of 75 percent by weight to 99
percent by weight, significant effects cannot be achieved.
The amount of use of the crosslinking agent is not less than 0.05
mole percent and not more than 0.5 mole percent with respect to the
hydrophilic unsaturated monomer, and it is preferably not less than
0.07 mole percent and not more than 0.2 mole percent. When the
amount of use of the crosslinking agent is less than 0.05 mole
percent or above 0.5 mole percent, the diffusing absorbency under
pressure of the absorbing agent is lowered, and the amount of the
water-soluble content increases. Therefore, it is industrially
unpreferable. In the polyfunctional unsaturated carboxylates having
a polyhydroxy alcohol having at least three hydroxy groups and
acrylic acid as an acid component, the amount of use of the
crosslinking agent should be calculated based on the compound
wherein all the hydroxy groups of the polyhydroxy alcohol having at
least three hydroxy groups are ester-linked to the unsaturated
carboxylates, i.e, based on the molecular weight of the main
component of the crosslinking agent.
For the dispersant used in the aqueous solution polymerization of
the present invention, a compound which is homogeneously dissolved
in water and is compatible with the crosslinking agent is
preferable, and in general, industrially obtainable compounds are
preferable. Examples of such dispersant include: a nonionic surface
active agent such as sorbitan aliphatic acid ester, polyoxyethylene
sorbitan aliphatic ester, polyglycerin aliphatic ester,
polyoxyethylene alkyl ether, polyoxyethylene alkyl phenol ether,
polyoxyethylene acyl ether, cane sugar aliphatic acid ester, and
the like; an anionic surface active agent such as higher alcohol
sulfate ester, alkyl naphthalene sulfonic acid salt,
alkylpolyoxyethylene sulphate salt, dialkyl sulfosuccinate, and the
like; a cationic surface active agent such as alkyl quarternary
ammonium salts, alkyl amine salts, and the like; an amphoteric
surface active agent such as alkylbetaine, lecithin, etc., a
polymer compound such as a lipophilic polymer having a carboxyl
group, a partially saponificated polyvinyl alcohol, methyl
cellulose, carboxymethyl cellulose, hydroxyethylcellulose, etc.
Among the above-listed dispersants, a water soluble surface active
agent, and water diffusible surface active agent are preferable,
and a nonionic surface active agent having at least 10 HLB
(hydrophilic-lipophilic balance) is the most preferable. The amount
of use of the dispersant is preferably in the range of 1-100
percent by weight with respect to the crosslinking agent, more
preferably in the range of 5-50 percent by weight. The amount of
use of the dispersant is preferably in the range of 0.005-0.5 parts
by weight with respect to 100 parts by weight of the precursor of
the absorbing agent resulting from the hydrophilic unsaturated
monomer.
The method of mixing (adding) the dispersant in the aqueous
solution polymerization is not especially limited. For example,
after directly mixing the crosslinking agent and the dispersant,
the mixed solution may be mixed with the hydrophilic unsaturated
monomer or aqueous solution thereof. Alternatively, after mixing
the solution or dispersion liquid of the crosslinking agent and the
dispersant, the hydrophilic unsaturated monomer or the solution
thereof may be mixed. After mixing the crosslinking agent, the
dispersant, the hydrophilic unsaturated monomer, or a part of the
solution, the resulting mixed solution may be mixed with the rest
of the hydrophilic unsaturated monomer and/or the solution. Or
after mixing the crosslinking agent, the solution or dispersion
liquid of the dispersant and a part of hydrophilic unsaturated
monomer or the solution thereof, the resulting solution may be
mixed with the rest of the hydrophilic unsaturated monomer or the
solution thereof. Among the above-listed mixing processes, the
process wherein after mixing the crosslinking agent, the dispersant
and a part of the hydrophilic unsaturated monomer or the solution
thereof, the resulting mixed solution is mixed with the rest of
hydrophilic unsaturated monomer or the solution thereof is
preferable. Further, the process wherein after mixing the
crosslinking agent, the dispersant, and a part of the acrylic acid
as hydrophilic unsaturated monomer, or the solution thereof, the
resulting mixed solution may be mixed with the rest of the
hydrophilic unsaturated monomer or the solution thereof
(neutralized polymer of acrylic acid) is more preferable.
When performing a polymerization of a hydrophilic unsaturated
monomer in the presence of the crosslinking agent and the
dispersant, the concentration of the hydrophilic unsaturated
monomer in solution is preferably in the range from 25 percent by
weight to a concentration (percent by weight) at the saturation
point, more preferably in the range between 30 percent by weight
and 45 percent by weight.
When starting the polymerization by the polymerization reaction,
for example, a radical polymerization initiator such as potassium
persulfate, ammonium persulfate, sodium persulfate,
t-butylhydroperoxide, hydrogen peroxide,
2,2'-azobis(2-amidinopropane)dihydrochloride, etc., or an active
energy ray, such as an ultraviolet ray, or an electron ray, etc.,
may be used. In the case of employing an oxidative radical
polymerization initiator, a redox polymerization may be carried out
by simultaneously using a reducing agent such as sodium sulfite,
sodium hydrogen sulfite, ferrous sulfate, L-ascorbic acid, etc. The
amount of use of the polymerization initiator is preferably in the
range of 0.001-2 mole percent, more preferably in the range of
0.01-0.5 mole percent.
The absorbing agent in accordance with the present invention is
prepared by applying a heat treatment to the precursor of the
absorbing agent obtained by the polymerization reaction in a
solution so as to have a water content of less than 10 percent and
an average particle diameter of 200-600 .mu.m and a content of
particles having a diameter of less than 106 .mu.m of not more than
10 percent by weight in the presence of a surface crosslinking
agent. The resulting precursor of the absorbing agent may have, for
example, undefined, globular (spherical), leaflet, granular shape,
and the like. Furthermore, the precursor of the absorbing agent may
be a primary particle, or a granule of primary particle. In
addition, when the water content is above 10 percent, or the
average particle diameter is outside the range of 200 .mu.m-600
.mu.m, or the ratio of the particle diameter having a diameter of
less than 106 .mu.m is above 10 percent by weight, the absorbing
agent having excellent dispersed absorbency under pressure, etc.,
cannot be achieved.
For the surface crosslinking agent in the present invention, a
known surface crosslinking agent is used, and a compound reactive
to a carboxyl group is suitable. Examples of such surface
crosslinking agent include: polyhydroxy alcohol compounds having at
least two hydroxy groups such as ethylene glycol, diethylene
glycol, propylene glycol, triethylene glycol, tetraethylene glycol,
polyethylene glycol, propylene glycol, 1,3-propanediol, dipropylene
glycol, 2,2,4-trimethyl-1,3-pentanediol, polypropylene glycol,
glycerol, polyglycerol, 2-butene-1,4-diol, 1,4-butanediol,
1,5-pentanediol, 1,6-hexanediol, 1,2-cyclohexanedimethanol,
1,2-cyclohexanol, trimethylolpropane, diethanolamine,
triethanolamine, polyoxypropylene, oxyethylene-oxypropylene block
copolymer, pentaerythritol, sorbitol, etc.; epoxy compounds such as
ethylene glycol diglycidyl ether, polyethylene glycol diglycidyl
ether, glycerol polyglycidyl ether, diglycerol polyglycidyl ether,
polyglycerol polyglycidyl ether, propylene glycol diglycidyl ether,
polypropylene glycol diglycidyl ether, glycidol, etc.; polyamine
compounds such as ethylenediamine, diethylenetriamine,
triethylenetetramine, tetraethylenepentamine,
pentaethylenehexamine, polyethyleneimine, etc.; polyisocyanate
compounds such as 2,4-tolylene diisocyanate, hexamethylene
diisocyanate, etc.; polyoxazoline compounds such as 1,2-ethylene
bisoxazoline, etc.; alkylene carbonate compounds such as
1,3-dioxolane-2-one, 4-methyl-1,3-dioxolane-2-one,
4,5-dimethyl-1,3-dioxolane-2-one, 4,4-dimethyl-1,3-dioxolane-2-one,
4-ethyl-1,3-dioxolane-2-one, 4-hydroxymethyl-1,3-dioxolane-2-one,
1,3-dioxane-2-one, 4-methyl-1,3-dioxane-2-one,
4,6-dimethyl-1,3-dioxane-2-one, 1,3-dioxopane-2-one, etc.;
haloepoxy compounds such as epichlorohydrin, epibromehydrine,
.alpha.-methylepichlorohydrin, etc.; a silane coupling agent such
as .gamma.-glycidoxypropyltrimethoxysilane,
.gamma.-aminopropyltrimethoxysilane, and the like; polyvalent
metallic compounds such as hydroxides and chlorides of metals:
zinc, calcium, magnesium, aluminum, iron, zirconium, etc. Only one
kind of the above-listed surface active agent may be adopted, or
two or more kinds thereof may be suitably mixed and adopted.
Especially when the surface crosslinking agent is combined with the
first surface crosslinking agent and the second surface
crosslinking agent having mutually different solubility parameters
(SP value), an absorbing agent with a still improved diffusing
absorbency under pressure can be obtained. In addition, the
solubility parameter is a value normally used as a factor
representing the polarity of the compound. In the present
invention, the solubility parameter .delta. (cal/cm.sup.3).sup.1/2
of the solvent described in pages 527-539 (polymer handbook, the
third edition (Wiley Interscience Co., Ltd.)) is applied. As to the
solubility parameter of the solvent which is not described in the
book, the value obtained by substituting the condensation energy
constant of Hoy described on page 525 to the formula of Small
described on page 524 of the book can be applied.
For the first surface crosslinking agent, a compound reactive to a
carboxylic group having a solubility parameter of more than 12.5
(cal/cm.sup.3).sup.1/2 is preferable, and a compound having a
solubility parameter of more than 13.0 (cal/cm.sup.3).sup.1/2 is
more preferable. Examples of the first crosslinking agent include:
ethylene glycol, propylene glycol, glycerol, pentaerythritol,
sorbitol, ethylene carbonate (1,3dioxorane-2-one), propylene
carbonate (4-methyl-1,3dioxorane-2-one), etc. However, the first
surface crosslinking agent is not limited to the above example.
Only one kind of such first surface crosslinking agent may be used,
or more than two kinds thereof may be used.
The second surface crosslinking agent is preferably a compound
which is reactive to a carboxyl group, having a solubility
parameter of less than 12.5 (cal/cm.sup.3).sup.1/2, and more
preferably in the range of 9.5-12.0 (cal/cm.sup.3).sup.1/2.
Examples of the second surface crosslinking agent include:
diethylene glycol, triethylene glycol, tetraethylene glycol,
dipropylene glycol, tripropylene glycol, 1,3-butanediol,
1,4-butanediol, 1,5-pentanediol, 2,4-pentanediol, 1,6-hexanediol,
2,5-hexanediol, trimethylolpropane, diethanolamine,
triethanolamine, ethylene glycol diglycidyl ether, polyethylene
glycol diglycidyl ether, glycerol polyglycidyl ether, diglycerol
polyglycidyl ether, polyglycerol polyglycidyl ether, propylene
glycol diglycidyl ether, polypropylene glycol diglycidyl ether,
ethylenediamine, diethylenetriamine, triethylene tetramine,
2,4-tolylene diisocyanate, hexamethylene diisocyanate,
4,5-dimethyl-1,3-dioxolane-2-one, epichlorohydrin, epibromohydrin,
and the like. The second crosslinking agent of the present
invention is not limited to the above-listed compound. Only one
kind of such second crosslinking agent may be used, or more than
two kinds thereof may be used.
For the surface crosslinking agent of the present invention, a
compound of at least one kind selected from the group of the first
surface crosslinking agent, and a compound of at least one kind
selected from the group of the second surface crosslinking agent
may be mixed and used.
Suitable amount of use of the surface crosslinking agent differs
depending on a compound to be used, or a combination, etc. However,
with respect to 100 parts by weight of solid portion of the
precursor of the absorbing agent, the surface crosslinking agent is
preferably used in an amount in the range of 0.001-10 parts by
weight, and more preferably in the range of 0.01-5 parts by weight.
In addition, when the first surface crosslinking agent and the
second surface crosslinking agent are used in combination, with
respect to 100 parts by weight of the solid portion of the
precursor of the absorbing agent, the first surface crosslinking
agent is used in a range of 0.01-5 parts by weight, and the second
surface crosslinking agent is used in a range between 0.001-1 parts
by weight. It is more preferable that the first surface
crosslinking agent is used in an amount of 0.1-2 parts by weight,
the second surface crosslinking agent is used in the range of
0.005-0.5 part by weight. By using the above surface crosslinking
agent, the precursor of the absorbing agent, i.e., the crosslinking
density in a vicinity of the surface of the absorbent resin can be
increased. When more than 10 parts by weight of the surface
crosslinking agent is used, it is not preferable not only for the
cost performances, but also in forming the suitable crosslinking
structure of the absorbing agent. On the other hand, when less than
0.001 part by weight of surface crosslinking agent is used, it is
difficult to obtain an effect of improving the diffusing absorbency
under pressure of the absorbing agent. Therefore, such condition is
not preferable.
When mixing the precursor of the absorbing agent with the surface
crosslinking agent, it is preferable to use water as a solvent. The
amount of use of water differs depending on the kinds, particle
diameter, water content, etc., of the precursor of the absorbing
agent. However, the amount of use of water is preferably above 0
and less than 20 parts by weight, more preferably in the range of
0.5-10 parts by weight, with respect to 100 parts by weight of the
solid portion of the precursor of the absorbing agent.
When mixing the precursor of the absorbing agent with the surface
crosslinking agent, a hydrophilic organic solvent may be used as a
solvent if necessary. Examples of such hydrophilic organic solvent
include: lower alcohol such as methyl alcohol, ethyl alcohol,
n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl
alcohol, t-butyl alcohol, etc.; ketone such as acetone, etc.; ether
such as dioxane, tetrahydrofuran, etc.; amide such as N,N-dimethyl
formamide, etc., sulfoxide such as dimethylsulfoxide, etc. Suitable
amount of use of the hydrophilic organic solvent varies depending
on kinds, particle diameter and water content of the precursor of
the absorbing agent. However, the content of the hydrophilic
organic solvent is preferably not more than 20 parts by weight,
more preferably in a range of from 0.1-10 parts by weight of 100
parts of the solid portion of the precursor of the absorbing
agent.
Then, when mixing the precursor of the absorbing agent with the
surface crosslinking agent, for example, after dispersing the
precursor of the absorbing agent in the hydrophilic organic
solvent, the surface crosslinking agent may be mixed. However, the
mixing method is not especially limited. Among various mixing
processes, the process wherein the surface crosslinking agent which
is dissolved in water and/or hydrophilic organic solvent, when an
occasion demands, is mixed with the precursor of the absorbing
agent directly or by spraying or dropping it is preferable. When
mixing with water, fine particles undissolvable in water or the
surface active agent, etc., may be used in combination.
The mixer for use in mixing the precursor of the absorbing agent
with the surface crosslinking agent preferably has a strong mixing
force so that both can be mixed homogeneously and surely. Examples
of such mixer include: a cylindrical mixer, a double wall conical
mixer, V-shaped mixer, ribbon type mixer, screw-type mixer,
flow-type oven rotary disk mixer, air-flow type mixer, two-arm type
kneader, internal mixer, grinding kneader, rotary mixer, screw type
extruder, etc.
After mixing the precursor of the absorbing agent with the surface
crosslinking agent, a heat treatment is applied so as to crosslink
around the surface of the precursor of the absorbing agent.
Suitable temperature of applying the heat treatment varies
depending on the surface crosslinking agent to be used. However, it
is preferably in the range between 80.degree. C. and 250.degree.
C., more preferably in the range between 120.degree. C. and
230.degree. C. When using the first surface crosslinking agent and
the second surface crosslinking agent in combination, the heat
treatment is suitably applied at a temperature not less than
160.degree. C. When the heat treatment is applied at temperature
below 80.degree. C. (below 160.degree. C. when using both the first
and second surface crosslinking agents), a uniform crosslinking
structure is not formed. Therefore, the absorbent resin having
excellent properties such as diffusing absorbency under pressure,
etc., cannot be obtained. Therefore, such condition is not
preferable. Besides, as it takes a long time for applying the heat
treatment, the productivity is low. On the other hand, when the
heat treatment is applied at above 250.degree. C., properties of
the precursor of the absorbing agent are lowered, which results in
poor performances of the absorbing agent. Thus, such condition is
not preferable.
The described heat treatment may be applied using general dryer,
heating oven, etc. Examples of such dryer include: groove type
mixing dryer, rotary dryer, disk dryer, fluidized layer dryer,
air-flow type dryer, infrared radiation dryer, etc.
The absorbing agent resulting from the described manufacturing
process has a diffusing absorbency under pressure of about 25 g/g
when 60 minutes has elapsed after the absorption started, and a
water soluble content in the range between 0 percent by weight and
7 percent by weight. Therefore, the absorbing agent has described
excellent absorbing properties. The reason why the absorbing agent
of the present invention shows excellent performances in its
diffusing absorbency under pressure, etc., is not specified.
However, it can be estimated that by using the dispersant as well
as a specific amount of the crosslinking agent prepared so as to
have a specific range of high-boiling point component, the
high-boiling point component is homogeneously dispersed in the
reaction system, and the crosslinking ability of the main component
thereof disturbed by the high-boiling point component can be fully
exhibited. In the meantime, the crosslinking reaction by the
high-boiling point component can be performed effectively. As a
result, the content of the water-soluble component can be
significantly reduced.
The described absorbing agent is provided with excellent absorbing
properties. Therefore, in the case of applying the absorbing agent
to an absorbent material, for example, sanitary goods such as a
paper diaper, sanitary napkin, incontinence pad, etc., even when
the resin concentration in the absorbent material is high, such
excellent properties that high diffusing absorbency under pressure,
and low water soluble content can be obtained irrespectively of the
structure of the absorbent material. In addition, such sanitary
goods have small amount of wet back after a long period of time,
very high liquid diffusivity, and a stability of keeping the amount
of water for a long period of time, thereby providing an absorbent
product which shows excellent performances. Such absorbing agent
can be suitably used, especially in sanitary goods, such as paper
diaper, sanitary napkin, a so-called incontinence pad, and the
like, to meet the demand of higher performances and thinner type
thereof. Thus, the described process enables the absorbing agent
which shows excellent properties to be manufactured.
In addition, deodorant, perfume, inorganic powder, foaming agent,
pigment, dye, hydrophilic short fiber, synthetic fiber, fertilizer,
oxidizing agent, reducing agent, water, salts, etc., may be added
to the resulting absorbing agent and the absorbent material
prepared by the process of the present invention, which enables the
absorbing agent, absorbent material and absorbent product to have
various functions.
Next, the absorbing agent, the absorbent material and the absorbent
product which show excellent properties (absorbing properties) such
as high liquid diffusivity and water absorbency under pressure,
etc., even if the resin concentration is raised will be
explained.
The absorbent material of the present invention includes at least
40 percent by weight of the absorbing agent having the diffusing
absorbency under pressure of at least 25 g/g when 60 minutes has
elapsed after the absorption is started, preferably 50 percent by
weight, more preferably 60 percent by weight, and most preferably
70 percent by weight. The absorbing agent having the diffusing
absorbency under pressure of at least 25 g/g measured when 60
minutes has elapsed after the absorption is started is unpreferable
because the liquid diffusivity in the lateral direction in the
absorbent material (high concentration) having an increased resin
concentration is lowered, and the absorbing capacity of the
absorbent material becomes small. It is preferable that the
diffusing absorbency under pressure after 60 minutes elapsed is not
less than 30 g/g. In addition, even when the absorbing agent having
the diffusing absorbency under pressure of not less than 25 g/g is
included, per unit absorbing capacity of the absorbent material
having the ratio of absorbing agent of less than 40 percent by
weight would be lowered. In the absorbent material of the present
invention, in addition to the diffusing absorbency under pressure,
when 60 minutes has elapsed after the absorption is started, it is
preferable to include the absorbing agent having the diffusing
absorbency under pressure of 15 g/g computed based on the value
measured when 30 minutes has elapsed after the absorption is
started. Furthermore, it is most preferable to include the
absorbing agent having the diffusing absorbency under pressure of
at least 15 g/g computed based on the value measured when 20
minutes has elapsed after the absorption is started.
Namely, it is preferable that the absorbing agent of the present
invention has the diffusing absorbency under pressure of not less
than 15 g/g when 30 minutes has elapsed after the absorption is
started and the diffusing absorbency under pressure of not less
than 25 g/g when 60 minutes has elapsed. It is more preferable that
the diffusing absorbency under pressure is not less than 15 g/g
when 20 minutes has elapsed after the absorption is started, and
the diffusing absorbency under pressure measured when 60 minutes
has elapsed after the absorption is started is not less than 25
g/g. It is the most preferable that the diffusing absorbency under
pressure measured when 60 minutes has elapsed is not less than 15
g/g, and the diffusing absorbency under pressure measured when 60
minutes has elapsed is not less than 30 g/g. The absorbing agent
has the diffusing absorbency under pressure of less than 15 g/g
when 30 minutes has elapsed after the absorption is started is
unpreferable because the liquid diffusivity in lateral direction
would be deteriorated, and the absorbing force of the absorbent
material is lowered.
Other than the absorbing agent, the absorbent material in
accordance with the present invention may include the hydrophilic
fiber if necessary. The structure of the absorbent material may be
the aforementioned structure, but is not especially limited.
However, it is preferable that the absorbing agent and the
hydrophilic fiber are homogeneously mixed so as to have the ratio
of the absorbing agent in the absorbent material not less than 40
percent by weight. It is still more preferable that the absorbing
agent and the hydrophilic fiber are uniformly mixed so as to have
the absorbing agent used in an amount not less than 50 percent by
weight, preferably 60 percent by weight, more preferably 70 percent
by weight with respect to the total amount of the absorbing agent
and the hydrophilic agent. By the described arrangement, the
absorbent material can fully exhibit the absorbing properties. In
addition, the higher is the resin concentration in the absorbent
material, the more obvious are the properties of the absorbing
agent and the absorbent material of the present invention.
In the case where the ratio of the hydrophilic fiber in the
absorbent material is relatively small, absorbent materials, i.e.,
hydrophilic fibers may be linked to one another using the described
adhesive binder.
The absorbing agent of the present invention is obtained by first
synthesizing the precursor of the absorbing agent and then applying
the heat treatment to the precursor of the absorbing agent in the
presence of a specific surface crosslinking agent. The precursor of
the absorbing agent has an average particle diameter in the range
of 200-600 .mu.m, and includes 10 percent by weight of particles
having a particle diameter of 106 .mu.m. Such precursor of the
absorbing agent is a resin for use in forming hydrogel by absorbing
a large amount of water. For example, the precursor of the
absorbing agent is synthesized by the aqueous solution
polymerization. Examples of the precursor of the absorbing agent
include: a partially neutralized crosslinked polymer of polyacrylic
acid, a hydrolyzed graft polymer of starch-acrylonitrile, a
neutralized graft polymer of starch-acrylic acid, a saponified
copolymer of vinyl acetate-acrylic ester, a hydrolyzed copolymer of
acrylonitrile or of acrylamide, or a crosslinked polymer thereof,
crosslinked denatured polyvinyl alcohol containing carboxyl group,
a copolymer of crosslinked isobutylene maleic anhydride, and the
like.
The precursor of the absorbing agent may be obtained by performing
a polymerization or a copolymerization of at least one kind
selected from unsaturated carboxylic acid such as (meth)acrylic
acid, maleic acid, maleic anhydride, fumaric acid, crotonic acid,
itaconic acid, .beta.-acryloxypropionic acid or the above acids in
a neutralized form, and further pulverizing or classifying the
polymer, if necessary, to have the above-defined particle diameter.
Among the above-listed monomers, (meth)acrylic acid and neutralized
form thereof are especially preferable.
The precursor of the absorbing agent may be a copolymer of the
monomer and the other monomer which is copolymerizable with the
monomer. Examples of the other monomer include: the exemplified
unsaturated monomer, i.e., the anionic unsaturated monomer and
salts thereof; a nonionic unsaturated monomer having a hydrophilic
group; a cationic unsaturated monomer, etc.
The precursor of the absorbing agent includes a carboxyl group. The
amount of the included carboxyl group in the precursor is not
especially limited. However, it is preferable that the carboxyl
group of not less than 0.01 equivalent value exists with respect to
100 g of the precursor of the absorbing agent. When the precursor
of the absorbing agent is, for example, a crosslinked polymer of
partially neutralized polyacrylic acid, it is preferable that the
ratio of unneutralized polyacrylic acid in the crosslinked compound
is in the range of 1-60 mole percent, more preferably 10-50 mole
percent.
It is preferable that the inside of the precursor of the absorbing
agent is crosslinked by reacting or copolymerizing with the
crosslinking agent including plural polymerizable unsaturated
groups and plural reactive groups. The precursor of the absorbing
agent may be the self crosslinkable type which does not require the
crosslinking agent. Examples of such crosslinking agent include:
N,N'-methylenebis(meth)acrylamide, (poly)ethylene glycol
di(meth)acrylate, (poly)propylene glycol di(meth)acrylate,
trimethylolpropane di(meth)acrylate, trimethylolpropane tri
(meth)acrylate, glycerol tri(meth)acrylate, glycerin acrylate
methacrylate, ethylene oxide denatured trimethylolpropane
tri(meth)acrylate, pentaerythritol tetra(meth)acrylate,
dipentaerythritol hexa(meth)acrylate, triallyl cyanurate, triallyl
isocyanurate, triallylphosphate, triallylamine, poly(meth)
aryloxyalkane, (poly)ethylene glycol diglycidyl ether, glycerol
diglycidyl ether, ethylene glycol, polyethylene glycol, propylene
glycol, glycerol, pentaerythritol, ethylenediamine,
polyethyleneimine, glycidyl(meth) acrylate, etc. Only one kind of
the above-listed crosslinking agent may be adopted, or two or more
kinds thereof may be suitably mixed and adopted. Among the
above-listed compounds, it is preferable to use the compound
including plural polymerizable unsaturated groups as a crosslinking
agent.
It is preferable that the crosslinking agent is used in an amount
in the range of 0.005-2 mole percent, more preferably in the range
of 0.05-1 mole percent. If the amount of use of the crosslinking
agent is less than 0.005 mole percent or more than 2 mole percent,
the diffusing absorbency under pressure of the absorbing agent will
be lowered Thus, such condition is unpreferable.
For the polymerization initiation in the polymerization reaction,
the above-exemplified radical polymerization initiator, or the
active energy ray, etc., may be used.
The described precursor of the absorbing agent does not have the
diffusing absorbency under pressure in the preferable range of the
present invention. Therefore, it is required to set the crosslinked
density in a vicinity of the surface of the precursor of the
absorbing agent higher than the inside thereof by adopting the
surface crosslinking agent. Namely, by crosslinking around the
surface of the precursor of the absorbing agent using a specific
surface crosslinking agent, the absorbing agent of the present
invention can be achieved.
The absorbing agent in accordance with the present invention is
prepared by adjusting the precursor of the absorbing agent obtained
by the aqueous solution polymerization so as to have an average
particle diameter of 200-600 .mu.m, and not more than 10 percent by
weight of the particle diameter below 106 .mu.m by classification,
etc., and thereafter applying a heat treatment to the precursor of
the absorbing agent in the presence of the specific surface
crosslinking agent. The precursor of the absorbing agent may be
formed in granules of the defined shape or in the shape of
undefined, granular, leaflet, granular, etc. Furthermore, the
precursor of the absorbing agent may be a primary particle, or a
granule of primary particles. In addition, in the case where the
average particle diameter is outside the range of 200-600 .mu.m,
and the case where the ratio of the particles having a diameter of
106 .mu.m is above 10 percent by weight, absorbing agents having
excellent properties such as diffusing absorbency under pressure,
etc., cannot be obtained.
The surface crosslinking agent is a combination of the first
surface crosslinking agent and the second crosslinking agent having
mutually different solubility parameters (SP value). Thus, it is
preferable that a compound of at least one kind selected from the
group of the first surface crosslinking agent and a compound of at
least one kind selected from the group of the second surface
crosslinking agent are mixed and used. In the case of adopting only
the first surface crosslinking agent of at least one kind, or the
second surface crosslinking agent of at least one kind, it may be
difficult to obtain the absorbing agent having excellent
performances of the diffusing absorbency under pressure, etc.
For the amount of use of the surface crosslinking agent, and the
method of mixing the precursor of the absorbing agent with the
surface crosslinking agent, the previously described amount of use,
the mixing method, the mixer, etc., may be used. In addition, in
the case of mixing the precursor of the absorbing agent with the
surface crosslinking agent, the previously described solvent (water
and/or hydrophilic organic solvent) may be used.
Suitable temperature of applying the heat treatment varies
depending on the surface crosslinking agent. However, it is
preferably in the range of 160.degree. C. to 250.degree. C. When
the heat treatment is applied at a temperature below 160.degree.
C., a homogeneous crosslinking structure may not be formed, and an
absorbing agent having excellent performances in its diffusing
absorbency under pressure, etc., cannot be obtained. Therefore,
such condition is not preferable. In addition, since a long time is
required for applying the heat treatment, a productivity would be
lowered. On the other hand, when applying the heat treatment at a
temperature above 250.degree. C., the properties of the precursor
of the absorbing agent are lowered, and the performances of the
absorbing agent are poor. Therefore, such condition is also not
preferable. The described heat treatment is performed using the
exemplified dryer or a heat oven.
The absorbing agent resulting from the described process has 15 g/g
of diffusing absorbency under pressure measured when 30 minutes has
elapsed after the absorption is started, and a diffusing absorbency
under pressure of 25 g/g after 60 minutes elapsed. As described,
the absorbent material contains such absorbing agent in an amount
of not less than 40 percent by weight. Therefore, the absorbing
agent and the absorbent material show described excellent absorbing
properties. Therefore, for example, in the case where it is used in
the absorbent product, the absorbent material can provide the
excellent properties such as high liquid diffusivity, water
retaining property, etc., even in the case of using a large amount
of absorbing agent or using the absorbent material having high
resin concentration.
The reason why the absorbent material using the absorbing agent of
the present invention shows excellent performances in its diffusing
absorbency under pressure, etc., is not clear. However, it can be
assumed that in the conventional absorbent material, the liquid
diffusion and the liquid transmission of the aqueous liquid in the
absorbent material is performed by capillarity of hydrophilic
fiber, whereas in the absorbent material of the present invention,
precise liquid diffusivity (liquid diffusing ability and liquid
transmitting ability) which the absorbing agent having excellent
diffusing absorbency under pressure has can be fully achieved even
in the absorbent material.
The absorbent product in accordance with the present invention
includes an absorbing layer including the absorbent material having
the described structure which is sandwiched between a liquid
permeable sheet and an impermeable sheet. Since the absorbent
product is provided with the absorbing layer including the
absorbent material having the described arrangement, the
above-mentioned excellent water absorbing properties can be
achieved. Examples of the absorbent product include: sanitary goods
such as paper diaper, sanitary napkin, incontinence pad, etc.
However, the present invention is not limited to the above-listed
absorbent products. Since the absorbent product of the present
invention has excellent absorbing properties, in its application of
paper diaper, etc., the leakage of urea can be prevented, and thus
the paper diaper can be maintained dry.
A sheet which is permeable to liquid (hereinafter referred to as a
liquid permeable sheet) is composed of a material which is
transmissive to aqueous liquid. For the material of the liquid
permeable sheet, nonwoven fabric, woven fabric; a porous synthetic
resin film such as polyethylene, polypropylene, polyester,
polyamide, etc., may be used. The sheet which is impermeable to
liquid (hereinafter referred to as liquid impermeable sheet) is
made of a material having properties that aqueous liquid is not
transmitted. For the material of the liquid impermeable sheet, for
example, a synthetic resin film such as polyethylene,
polypropylene, ethylenevinylacetate, polyvinyl chloride; a film
composed of the above-mentioned synthetic resin and nonwoven
fabric, a film composed of the synthetic material of synthetic
resin and woven fabric, etc., may be used. In addition, a liquid
impermeable sheet may have property of transmitting vapor.
The arrangement of the absorbing layer is not particularly limited,
as long as the described absorbent material is included. Similarly,
the method of manufacturing the absorbing layer is not especially
limited. Furthermore, the method of sandwiching the absorbing layer
between the liquid permeable sheet and the liquid impermeable
sheet, and the method of manufacturing the absorbent product are
not especially limited.
In addition, deodorant, perfume, inorganic powder, foaming agent,
pigment, dye, hydrophilic short fiber, synthetic fiber, fertilizer,
oxidizing agent, reducing agent, water, salts, etc., may be added
to the resulting absorbing agent, absorbent material or absorbent
product prepared by the process of the present invention, which
enables them to have various functions.
For a fuller understanding of the nature and advantages of the
invention, reference should be made to the ensuing detailed
description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a device of measuring
a diffusing absorbency under pressure as one of the properties of
an absorbing agent of the present invention;
FIG. 2 is a schematic cross-sectional view showing an essential
part of the measuring device of FIG. 1;
FIG. 3 is an explanatory view showing a diffusing direction of
physiological saline solution.
FIG. 4 is a schematic crosssectional view of a device of measuring
a water absorbency under pressure as one of the properties of the
absorbing agent of the present invention;
FIG. 5 is a cross-sectional view of the device of measuring the
diffusing absorbency under pressure as one of the properties of the
absorbent product or the absorbent material of the present
invention;
FIG. 6 is a cross-sectional view showing an essential part of the
measuring device of FIG. 5; and
FIG. 7 is an explanatory view showing the diffusing direction of
physiological saline solution in the measuring device of FIG.
5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, this invention is illustrated by the following
examples of some preferred embodiments in comparison with
comparative examples not according to the invention. However, this
invention is not limited to the undermentioned examples. Evaluation
methods of properties of absorbing agents, absorbent materials, and
absorbent products performed in the examples and comparative
examples are as follows.
(a) Absorbency under pressure i) tea bag method 0.2 gram of the
absorbing agent (precursor of the absorbing agent) was uniformly
placed into a bag like a tea-bag (40 mm.times.150 mm) made of
nonwoven fabric, and was immersed into a solution of 0.9 percent by
weight of sodium chloride (physiological saline solution). After
leaving it for 60 minutes, the bag was taken out. Then, the bag was
subjected to hydro-extraction for a predetermined period of time,
and the weight W.sub.1a (g) of the bag was measured. Further, the
same processes are carried out without using the absorbing agent,
and the weight W.sub.0a (g) of the bag was measured. The absorbency
under pressure (g/g) was calculated from the weights W.sub.1a and
W.sub.0a in accordance with the following equation: Absorbency
under pressure (g/g)=(Weight W.sub.1a (g)-Weight W.sub.0a
(g))/Weight of Absorbing Agent (g) ii) centrifugal separation
method 0.2 gram of the absorbing agent was uniformly placed into a
bag (60 mm.times.60 mm) made of nonwoven fabric, and was immersed
into a solution of sodium chloride of 0.9 percent by weight
(physiological saline solution). After leaving it for 60 minutes,
the bag was taken out. Then, the bag was subjected to
hydroextraction for 3 minutes at 250 G using a centrifugal
separator, the weight W.sub.1b (g) of the bag was measured.
Further, the same processes are carried out without using the
absorbent resins, and the weight W.sub.0b (g) of the bag was
measured. The absorbency under pressure (g/g) was calculated from
the weights W.sub.1b and W.sub.0b from the following equation:
Absorbency under pressure (g/g)=(Weight W.sub.1b (g)-Weight
W.sub.0b (g))/Weight of Absorbing agent (g).
(b) water soluble component content
In 1000 ml of deionized water, 0.500 g of absorbing agent
(precursor of the absorbing agent) was diffused, and after
agitating it for 16 hours, the mixture was filtered off through a
filter paper. Next, 50 g of the resulting filtrate was collected in
a 100 ml beaker. To the filtrate were added 1 ml of 0.1N sodium
hydroxide solution, 10.00 ml of N/200 methylglycol chitosan
solution and 4 drops of 0.1 percent toluidine blue solution.
Thereafter, the solution in the beaker was colloidal-titrated by a
solution of N/400 potassium polyvinyl sulfate. When the solution
changed its color from blue to red purple, it was determined that
the titration was completed, and the amount of titration A (ml) was
calculated. Further, the same processes were carried out using 50 g
of deionized water in place of 50 g of filtrate, and the amount of
titration B (ml) was calculated as blank titration. The water
soluble component content was calculated from amount of titration A
and B, and neutralization.times.(mole percent) of acrylic acid
added to the absorbing agent in accordance with the following
equation.
(c) Diffusing Absorbency under pressure of the Absorbing Agent
First, the device used in measuring the diffusing absorbency under
pressure of the absorbing agent will be briefly explained below in
reference to FIG. 1 and FIG. 2.
As shown in FIG. 1, the measuring device includes a balance 1, a
container 2 placed on the balance 1 of a predetermined capacity, an
air-intake pipe 3, a conduit 4, a glass filter 6, and a measuring
section 5 that is placed on the glass filter 6. The container 2 has
an opening 2a on its top portion and an opening 2b on its side
portion, and the air-intake pipe 3 is inserted through the opening
2a while the conduit 4 is fixed to the opening 2b. Further, a
predetermined amount of physiological saline solution 12 is placed
in the container 2. The lower end portion of the air-intake pipe 3
is dipped into the physiological saline solution 12. The glass
filter 6 has a diameter of 70 mm. The container 2 and the glass
filter 6 are connected to each other through the conduit 4. The
glass filter 6 is fixed at a position slightly above the lower end
of the air-intake pipe 3.
As shown in FIG. 2, the measuring section 5 is provided with a
paper filter 7, a sheet 8, a supporting cylinder 9, a metal gauze
10 that is affixed to the bottom of the supporting cylinder 9, and
a weight 11. In the measuring section 5, the paper filter 7, the
sheet 8, and the supporting cylinder 9 (that is, the metal gauze
10) are placed on the glass filter 6 in this order, and the weight
11 is placed on the metal gauze 10 inside the supporting cylinder
9. The sheet 8 is made of polyethylene terephthalate (PET) and is
formed in a doughnut shape with a thickness of 0.1 mm having an
opening at a center with a diameter of 18 mm. The supporting
cylinder 9 has an inner diameter of 60 mm.
The metal gauze 10, made of stainless steel, is designed to be
400-mesh (the size of each mesh: 38 .mu.m). Thus, a predetermined
amount of the absorbing agent is uniformly scattered on the metal
gauze 10. The weight 11 is adjusted so that it can uniformly apply
a load of 20 g/cm.sup.2 to the metal gauze 10, that is, to the
absorbing agent.
The diffusing absorbency under pressure of the absorbing agent was
measured by using the measuring device having the above-mentioned
arrangement. The following description will discuss the measuring
method.
First, predetermined preparatory operations were carried out, such
as a predetermined amount of physiological saline solution 12 was
put into the container 2; the air-intake pipe 3 was inserted into
the container 2; and other preparatory operations were performed.
Next, the paper filter 7 was placed onto the glass filter 6. The
sheet 8 was placed on the paper filter 7 in such a manner that its
opening was positioned at the center of the glass filter 6. In the
meantime, 1.5 g of the absorbent resins (preferably, the absorbent
resin prepared so as to have a particle diameter of 300-500 .mu.m
by classification, etc.) was uniformly scattered on the metal gauze
10 inside the supporting cylinder 9, and the weight 11 was placed
on the absorbing agent.
Successively, the metal gauze 10, that is, the supporting cylinder
9 whereon the absorbing agent and the weight 11 were placed, was
placed on the sheet 8, in such a manner that the center of the
supporting cylinder 9 coincides with the center of the glass filter
6.
Then, the weight W.sub.2 (g) of the physiological saline solution
12, which had been absorbed by the absorbing agent for 20, 30 or 60
minutes from the time when the supporting cylinder 9 was placed on
the sheet 8 was measured by the balance 1. Further, as shown in
FIG. 3, after passing through the opening of the sheet 8, the
physiological saline solution 12 was absorbed by the absorbing
agent while being uniformly diffused in a lateral direction.
The diffusing absorbency under pressure (g/g) of the absorbing
agent when 20, 30 and 60 minutes has elapsed after the absorption
was started was calculated from the following equation: Diffused
Absorbing ratio of the Absorbing agent (g/g)=Weight W.sub.2
(g)/Weight (g) of the Absorbing agent (g).
(d) Absorbency under Pressure of the Absorbing Agent
First, the device used in measuring the absorbency under pressure
of the absorbing agent will be briefly explained in reference to
FIG. 4.
As shown in FIG. 4, the measuring device includes a buret 21, a
measuring plate 22, a conduit 23, a glass filter 24 placed on the
measuring plate 22, and a measuring section 25 placed on the glass
filter 24. The buret 21 is formed in substantially T-shape and
includes a main conduit 21a and side conduits 21b. The main conduit
21a has an opening 21c on its top portion and an opening 21d at its
bottom portion, and a stopcock 26 is fitted to the opening 21c,
while the conduit 23 is mounted to the opening 21d. In addition,
the side conduit 21b is projected at a center on the side face of
the main conduit 21a, and the leading end thereof has an opening in
an upward direction. The measuring plate 22 has an upper surface
with a diameter of 70 mm. The buret 21 and the measuring plate 22
are connected through the conduit 23. In the buret 21, the
measuring plate 22, and the conduit 23, i.e., a continuous portion,
a predetermined amount of artificial urea 20 is placed. The main
conduit 21a of the buret 21 has a scale. In the buret 21, the
position of the liquid face 20a in the side conduit 21b has a
predetermined height position below the liquid face 20b of the main
conduit 21a.
The measuring section 25 includes a filter paper 27, a supporting
cylinder 28, a nonwoven fabric 29 laminated on the bottom portion
of the supporting cylinder 28 and a weight 30. The measuring
section 25 is arranged such that the filter paper 27, and the
supporting cylinder 28 (nonwoven fabric 29) are placed in this
order on the glass filter 24, and the weight 30 is placed in the
supporting cylinder 28, i.e., on the nonwoven fabric 29. The glass
filter 24 is formed so as to have a diameter of 70 mm. The
supporting cylinder 28 has an inner diameter of 55 mm. When placing
the measuring section 25, the position of the filter paper 27 is
set at the same position as the liquid face 20a of the side
conduits 21b. Then, a predetermined amount of the absorbing agent
is uniformly dispersed on the nonwoven fabric 29. The weight 30 is
adjusted so as to uniformly apply a load of 20 g/cm.sup.2, to the
nonwoven fabric 29, that is, to the absorbing agent.
Using the measuring device of the described arrangement, the
absorbency under pressure of the absorbing agent was measured in
the following manner.
First, a predetermined amount of artificial urea 20 (composition:
1.9 percent by weight of urea, 0.8 percent by weight of NaCl, 0.1
percent by weight of CaCl.sub.2, and 0.1 percent by weight of
MgSO.sub.4) was prepared, and was poured in the above-mentioned
connected portion. Then, the opening 21c of the buret 21 was closed
with the stopcock 26, and a predetermined preparatory operation was
performed such as placing the measuring plate 22 at a predetermined
height position. Then, the filter paper 27 was placed on the glass
filter 24 provided at the central portion of the measuring device
22. In the meantime, 0.20 g of the absorbing agent was uniformly
diffused in the inside of the supporting cylinder 28, i.e., on the
nonwoven fabric 29, and the weight 30 was placed on the absorbing
agent.
Then, on the filter paper 27, the nonwoven fabric 29, i.e., the
supporting cylinder 28 for storing therein the absorbing agent and
the weight 30, was placed in such a manner that the center thereof
coincided with the center of the glass filter 24.
After placing the supporting cylinder 28 on the filter paper 27, a
volume V.sub.1 (ml) of the artificial urea 20 absorbed by the
absorbing agent in 30 minutes was measured by reading the scale of
the buret 21. Then, from the obtained volume V.sub.1, the
absorbency under pressure (ml/g) of the absorbing agent measured
when 30 minutes has elapsed after the absorption was started from
the following formula: Absorbency under pressure of the absorbing
agent (ml/g)=volume V.sub.1 (ml)/weight of the absorbing agent
(g).
(e) Diffusing absorbency under Pressure of the Absorbent Product
(Absorbent Material)
First, the device of measuring the diffusing absorbency under
pressure of the absorbent product (or absorbent material, for
convenience, both absorbent material and the absorbent product are
simply referred to as an absorbent product) will be briefly
explained in reference to FIG. 5 and FIG. 6. For convenience in
explanation, members having the same functions as the
aforementioned device used in measuring the diffusing absorbency
under pressure will be designated by the same reference numerals,
and thus the descriptions thereof shall be omitted here.
As described in FIG. 5, the measuring device includes: a balance 1,
a container 2, an air-intake pipe 3, a conduit 4, and a glass
filter 6 having a diameter of 120 mm, and a measuring section 15
placed on the glass filter 6. As shown in FIG. 6, the measuring
section 15 includes a filter paper 7, a sheet 8, an angular
supporting cylinder 19 and a weight 11. The described metal gauze
is not provided.
The measuring section 15 includes the filter paper 7, the sheet 8
and the angular supporting cylinder 19 which are placed on the
glass filter 6 in this order and the weight 11 placed on the inside
of the angular supporting cylinder 19. The sheet 8 is made of
polyethylene terephthalate, and is formed in a rectangular shape
with an opening with a size of 12.5 mm.times.100 mm at the center
and a thickness of 0.1 mm. The angular supporting cylinder 19 is
formed so as to have an inner size of 100 mm.times.100 mm. Further,
a predetermined size of the absorbent product is placed in the side
of the angular supporting cylinder 19. Other arrangements of the
measuring device are the same as the aforementioned measuring
device for use in measuring the diffusing absorbency under
pressure.
The diffusing absorbency under pressure of the absorbent product
was measured using the measuring device having the described
arrangement in the following manner.
First, the absorbent product is formed with a size of 100
mm.times.100 mm. Then, predetermined preparatory operations were
performed. Then, the filter paper 7 was placed on the glass filter
6, and the sheet 8 was placed on the filter sheet 7 in such a
manner that its opening coincided with the center of the glass
filter 6. Then, the angular supporting cylinder 19 was placed on
the sheet 8 such that the central portion thereof coincided with
the central portion of the glass filter 6.
Thereafter, the absorbent product was placed in the inside of the
angular supporting cylinder 19, i.e., on the sheet 8, and the
weight 11 was placed on the absorbent product. The placement
operations of the absorbent product and the weight 11 were quickly
performed.
From the time at which the absorbent product was placed on the
sheet 8, a weight W.sub.3 (g) of physiological saline solution 12
absorbed by the absorbent product was measured over 30 minutes or
60 minutes. In addition, as shown in FIG. 7, after passing through
the opening of the sheet 8, the physiological saline solution 12
was absorbed by the absorbent product while the physiological
saline solution 12 was being uniformly dispersed in the absorbent
product in a lateral direction.
Then, based on the weight W.sub.3, the diffusing absorbency under
pressure (g/g) of the absorbent product was measured when 30
minutes or 60 minutes has elapsed after the absorption was started
from the following formula: Diffusing absorbency under pressure
(g/g) of the Absorbent Product=Weight W.sub.3 (g)/Weight (g) of the
Absorbent Product.
The crosslinking agents used in Examples 1-6 and comparative
examples 1-3 were prepared in the following manner.
Preparation 1
In an one-liter flask with four openings provided with an agitator,
a water-separator with a cooling tube, a thermometer and an
air-introducing tube, 134 g of trimethylolpropane, 238 g of acrylic
acid, 170 g of toluene, 24 g of p-toluenesulfonic acid and 0.6 g of
hydroquinone were fed, and the flask was heated to 130.degree. C.
while introducing air thereinto.
Produced water was distilled off from a reaction system by an
azeotropic dehydration with toluene, while a reaction was performed
for a predetermined time.
Then, the reaction solution was transferred to a separating funnel,
and after neutralizing the unreacted acrylic acid with 500 g of 10
percent by weight of NaOH aqueous solution and 300 g of 5 percent
by weight of NaOH aqueous solution, the reaction solution was
layered and washed with water (500 g each) several times until the
washed liquid was neutralized. Then, to an organic layer, 0.06 g of
hydroquinone monomethyl ether was added, and the toluene was
distilled under reduced pressure, thereby obtaining a reaction
product.
The reaction product was analyzed using gas chromatography (GC),
and gel permeation chromatography (GPC). As a result, the ratio of
essential components of the cross-linking agent including
trimethylolpropane triacrylate, trimethylolpropane diacrylate and
trimethylolpropane diacrylatemono(.beta.-acryloyloxypropionate) to
a high boiling-point compound including a compound having at least
two trimethylolpropane structures was 84/16. By the described
reaction and operation, a cross-linking agent A having a ratio in
weight of the essential component to the high boiling-point
compound of 84/16 was obtained.
Preparation 2
The same reaction as preparation 1 was performed in the same manner
except that the reaction time was set longer than preparation 1,
and a cross-linking agent B having a ratio by weight of a
cross-linking main component to a high-boiling point component of
78/22 was obtained.
Preparation 3
The same reaction as preparation 1 was performed in the same manner
except that the reaction time was set shorter than preparation 1,
and a cross-linking agent C having a ratio by weight of a
cross-linking main component to a high-boiling point component of
89/11 was obtained.
Preparation 4
The same reaction as preparation 2 was performed in the same manner
except that the reaction time was set still longer than preparation
2, and a comparative cross-linking agent having a ratio by weight
of a comparative cross-linking main component to a high-boiling
point component of 72/28 was obtained.
Next, using crosslinking agents obtained from Preparation
1-Preparation 4, a polymerization of a hydrophilic unsaturated
monomer was performed in a solvent.
EXAMPLE 1
In 414 g of acrylic acid (hydrophilic unsaturated monomer), 4.8 g
of the crosslinking agent A and 1.0 g of polyoxyethylenesorbitan
monostearate (dispersant) were dissolved. To the mixture, 4382 g of
37 percent by weight of sodium acrylate (hydrophilic unsaturated
monomer) and 551 g of ion exchanged water were added to give a
reaction solution. In a stainless steel reactor of two-arms type
kneader with a cover equipped with a jacket (volume content: 10 L)
with two sigma blades, the reaction solution was poured, and the
reaction system was displaced by introducing nitrogen gas while
maintaining the reaction solution at 30.degree. C. Then, while
agitating the reaction solution maintained at 30.degree. C., 2.40 g
of sodium persulfate and 0.12 g of L-ascorbic acid were added to
the reaction solution so as to start the polymerization. After
leaving it for 40 minutes, a resulting finely divided
water-containing gel-like polymer was taken out.
The resulting finely divided water-containing gel-like polymer was
placed on a wire netting of 50 mesh and dried under hot air at
150.degree. C. for 90 minutes. Then, the resulting dried polymer
was pulverized by a vibrating mill and further classified by a wire
netting of 20 mesh. As a result, an absorbent resin of undefined
shape with a water content of 4 percent, an average particle
diameter of 350 .mu.m and ratio of particles having a diameter of
106 .mu.m or below of 3 percent by weight was obtained. Namely, a
precursor of the absorbing agent was obtained. The absorbency under
pressure by tea bag method and the water soluble content of the
resulting precursor of the absorbing agent (hereinafter simply
referred to as results) are shown in Table 1.
EXAMPLE 2
The same reaction as Example 1 was performed in the same manner
except that 4.8 g of the crosslinking agent B was used in place of
the crosslinking agent A used in Example 1. As a result, an
absorbent resin of undefined shape with a water content of 5
percent, an average particle diameter of 300 .mu.m and ratio of
particles having a diameter of 106 .mu.m or below of 6 percent by
weight was obtained. Namely, a precursor of the absorbing agent was
obtained. The results of this example are shown in Table 1.
EXAMPLE 3
The same reaction as Example 1 was performed in the same manner
except that 4.8 g of the crosslinking agent C was used in place of
the crosslinking agent A used in Example 1. As a result, an
absorbent resin of undefined shape with a water content of 8
percent, an average particle diameter of 480 .mu.m and ratio of
particles having a diameter of 106 .mu.m or below of 0.5 percent by
weight was obtained. Namely, a precursor of the absorbing agent was
obtained. The results of this example are shown in Table 1.
EXAMPLE 4
The same reaction as Example 1 was performed in the same manner
except that the amount of use of the crosslinking agent A was
changed from 4.8 g to 6.8 g. As a result, an absorbent resin of
undefined shape with a water content of 5 percent, an average
particle diameter of 380 .mu.m and ratio of particles having a
diameter of 106 .mu.m or below of 2 percent by weight was obtained.
Namely, a precursor of the absorbing agent was obtained. The
results of this example are shown in Table 1.
EXAMPLE 5
The same reaction as Example 1 was performed in the same manner
except that the amount of use of the crosslinking agent A was
changed from 4.8 g to 13.6 g. As a result, an absorbent resin of
undefined shape with a water content of 4 percent, an average
particle diameter of 400 .mu.m and ratio of particles having a
diameter of 106 .mu.m or below of 1 percent by weight was obtained.
Namely, a precursor of the absorbing agent was obtained. The
results of this example are shown in Table 1.
EXAMPLE 6
In 29 g of acrylic acid (hydrophilic unsaturated monomer), 6.8 g of
the crosslinking agent A and 2.3 g of partially saponified
polyvinyl alcohol (dispersant) were dissolved. To the mixture, 4382
g of 37 percent by weight of sodium acrylate (hydrophilic
unsaturated monomer), 385 g of acrylic acid (hydrophilic
unsaturated monomer) and 283 g of ion exchanged water were added to
give a reaction solution. Thereafter, the same reaction as Example
1 was performed. As a result, an absorbent resin of undefined shape
with a water content of 8 percent, an average particle diameter of
520 .mu.m and ratio of particles having a diameter of 106 .mu.m or
below of 0 percent by weight was obtained. Namely, a precursor of
the comparative absorbing agent was obtained. The results of this
example are shown in Table 1.
Comparative Example 1
The same reaction as Example 1 was performed in the same manner
except that 4.8 g of comparative crosslinking agent was used in
place of the crosslinking agent A used in Example 1. As a result, a
comparative absorbent resin of undefined shape with a water content
of 5 percent, an average particle diameter of 340 .mu.m and ratio
of particles having a diameter of 106 .mu.m or below of 5 percent
by weight was obtained. Namely, a precursor of the comparative
absorbing agent was obtained. The results of this example are shown
in Table 1.
Comparative Example 2
The same reaction as Example 1 was performed in the same manner
except that polyoxyethylenesorbitan monostearate used in Example 1
was not used. As a result, a comparative absorbent resin of
undefined shape with a water content of 4 percent, an average
particle diameter of 370 .mu.m and ratio of particles having a
diameter of 106 .mu.m or below of 3 percent by weight was obtained.
Namely, a precursor of the comparative absorbing agent was
obtained. The results of this example are shown in Table 1.
Comparative Example 3
The same reaction as Example 1 was performed in the same manner
except that the amount of use of the crosslinking agent A was
changed from 4.8 g to 2.0 g. As a result, an absorbent resin of
undefined shape with a water content of 5 percent, an average
particle diameter of 390 .mu.m and ratio of particles having a
diameter of 106 .mu.m or below of 2 percent by weight was obtained.
The results of this example are shown in Table 1.
TABLE 1 Absorbency Water soluble by tea bag Content method (g/g) (%
by weight) Example 1 43 6 Example 2 44 7 Example 3 43 6 Example 4
40 4 Example 5 38 3 Example 6 40 5 Comparative 44 8 Example 1
Comparative 44 8 Example 2 Comparative 52 14 Example 3
EXAMPLE 7
To 100 parts by weight of the precursor of the absorbing agent
resulting from Example 1, a surface crosslinking agent composed of
0.5 parts by weight of glycerol (SP value: .delta.=16.5
(cal/cm.sup.3).sup.1/2) as the first surface crosslinking agent,
0.1 parts by weight of ethylene glycol diglycidyl ether (SP
value:.delta.=10.2 (cal/cm.sup.3).sup.1/2) as the second
crosslinking agent, 3 parts by weight of water and 1 part by weight
of isopropyl alcohol was mixed. By applying a heat treatment to the
resulting mixture for 40 minutes at 200.degree. C., and absorbing
agent was obtained. The absorbency by the tea bag method, the water
soluble content, the diffusing absorbency under pressure and the
absorbency under pressure of the absorbing agent (hereinafter
simply referred to as results) are shown in Table 2.
EXAMPLES 8 AND 9
The same heat treatment as Example 7 was performed in the same
manner except that 100 parts by weight of the precursor of the
absorbing agents resulting from Examples 4 and 5 were used, and
respective absorbing agents were obtained. The results of these
examples are shown in Table 2.
Comparative Examples 4 and 5
The same heating process as Example 7 was performed in the same
manner except that 100 parts by weight of the precursor of the
comparative absorbing agents resulting from Comparative Examples 1
and 3 were used, and respective comparative absorbing agents were
obtained. The results of these examples are shown in Table 2.
Comparative Example 6
A graft polymer of partially neutralized and crosslinked
starch-acrylate (Sunwet IM3900P available from Hoechst Celanese
Co., Ltd.) was used as a comparative absorbing agent. The results
of this comparative example are shown in Table 2.
Comparative Example 7
A polymer of partially neutralized and crosslinked acrylate
(Daiyawet US2-45Z; available from Mitsubishi Petrochemical Co.,
Ltd.) was used as a comparative absorbing agent. The results of
this comparative example are shown in Table 2.
Comparative Example 8
A polymer of partially neutralized and crosslinked acrylate
(Aquakeep SA-60; available from Sumitomo Seika Co., Ltd.) was used
as a comparative absorbing agent. The results of this comparative
example are shown in Table 2.
Comparative Example 9
A high-molecular absorbing agent was taken out from a paper diaper
(Mammy poco available from Unicharm Co., Ltd.) as a comparative
absorbing agent. The results of this comparative example are shown
in Table 2.
TABLE 2 Water Diffusing absorbency Absorbency Absor- Soluble under
pressure (g/g) under bency Content After After pressure (g/g)
(weight %) 20 min. 60 min. (ml/g) Example 7 42 6 17 31 29 Example 8
40 4 20 34 30 Example 9 39 3 23 32 29 Comp. 42 8 16 29 28 Example 4
Comp. 47 14 12 27 31 Example 5 Comp. 44 3 4 12 28 Example 6 Comp.
54 68 7 12 26 Example 7 Comp. 58 25 10 21 30 Example 8 Comp. 51 4 4
9 27 Example 9
EXAMPLE 10
75 parts by weight of the absorbing agent obtained from Example 7
and 25 parts by weight of ground wood pulp (hydrophilic fiber) were
mixed by a mixer using a dry method. The resulting mixture was
formed into a web with a size of 100 mm.times.100 mm. Thereafter,
by pressing the web for 1 minute with a pressure of 2 kg/cm.sup.2,
an absorbent product composed of an absorbent material with a basis
weight of around 0.035 g/cm.sup.2 was obtained. The diffusing
absorbency under pressure of the resulting absorbent product when
60 minutes elapsed (hereinafter simply referred to as results) are
shown in Table 3.
EXAMPLES 11 AND 12
An absorbent material was prepared in the same manner as Example 10
except that absorbing agents obtained from Examples 8 and 9 were
used in place of the absorbing agent used in Example 10, and
respective absorbent products were obtained. The results are shown
in Table 3.
Comparative Examples 10-15
An absorbent material was prepared in the same manner as Example 10
except that absorbing agents obtained from Comparative Examples 4-9
were used in place of the absorbing agent used in Example 10, and
respective absorbent products were obtained. The results are shown
in Table 3.
TABLE 3 Diffusing absorbency under pressure of absorbent product
when 60 min. elapsed (g/g) Example 10 24.7 Example 11 25.5 Example
12 25.2 Comparative 23.4 Example 10 Comparative 24.1 Example 11
Comparative 10.7 Example 12 Comparative 10.8 Example 13 Comparative
15.8 Example 14 Comparative 8.6 Example 15
EXAMPLE 13
75 parts by weight of absorbing agent obtained from Example 7 and
75 parts by weight of groundwood pulp (hydrophilic fiber) were
mixed by a mixer using a dry method. The resulting mixture was
formed into a web using a batch-type pneumatic molding device which
had a wire screen of 400 mesh, a web with a size of 120
mm.times.400 mm was formed. Further, by pressing the web for 5
seconds with a pressure of 2 kg/cm.sup.2, an absorbent material
with a basis weight of around 0.047 g/cm.sup.2 was obtained.
Thereafter, by laminating a back sheet composed of polypropylene
impermeable to liquid with a leg gather, the absorbent material and
a top sheet made of polypropylene permeable to liquid in order
using a both sided tape, and by putting two tape jippers to the
adhesive material, an absorbent product (i.e., paper diaper) was
obtained. The weight of the absorbent product was 46 g.
The absorbent product was put on a so-called Kewpie doll (height:
55 cm; and weight: 5 kg), and the doll was placed facing down.
Thereafter, a tube was inserted between the absorbent product and
the doll, and onto the position corresponding to the portion from
which urine was to be discharged, 50 ml of physiological saline
solution was poured each time, and a total amount of 250 ml of
physiological saline solution was poured with an interval of 20
minutes. Then, after leaving the doll for 16 hours at 37.degree.
C., the absorbent product was taken out.
At the center of the absorbing portion of the absorbent product
thus taken out, 10 pieces of so-called kitchen towels are
laminated. Then, 10 kg was loaded on these kitchen towels for 1
minute, and the the amount of wet back of the kitchen towel, i.e.,
the obtained amount (g) of the physiological saline solution from
the absorbent product was measured. The obtained result of this
example is shown in Table 4.
EXAMPLES 14 AND 15
An absorbent product was prepared in the same manner as Example 13
except that absorbent agents obtained from Examples 8 and 9 were
used in place of the absorbing agent used in Example 13. The
obtained amount (g) of the physiological saline solution from the
absorbent product was measured. The results of these examples are
shown in Table 4.
Comparative Examples 16 and 17
An absorbent product was prepared in the same manner as Example 13
except that absorbent agents obtained from Comparative Examples 4
and 5 were used in place of the absorbing agent used in Example 13.
The obtained amount (g) of the physiological saline solution from
the absorbent material was measured. The results of these examples
are shown in Table 4.
TABLE 4 Amount of Wet Back (g) Example 13 3.1 Example 14 2.3
Example 15 0.7 Comparative 6.6 Example 15 Comparative 9.2 Example
17
As is clear from Tables 1-4, the absorbing agent of the present
invention has high diffusing absorbency under pressure and low
water soluble content. The absorbent product prepared using an
absorbent material having high resin concentration has excellent
properties (absorbent properties) also in that the amount of wet
back of the aqueous liquid after a long time elapsed is small, and
liquid diffusivity and stability with time of holding a constant
amount of water (absorbing properties) are high.
EXAMPLE 16
To 5500 g of aqueous solution of 30 percent by weight of sodium
acrylate (neutralization rate of 65 mole percent) as a monomer, was
dissolved 18.49 g of polyethylene glycol diacrylate (average
additional mole number of ethylene oxide=8) to prepare a reaction
solution. Next, a deairing operation of the reaction solution was
performed for 30 minutes under an atmosphere of nitrogen. In a
stainless steel reactor of two-arms type kneader with a cover
equipped with a jacket (volume content: 10 L) with two sigma
blades, the reaction solution was poured, and the reaction system
was displaced by introducing nitrogen gas while maintaining the
reaction solution at 30.degree. C. Then, while agitating the
reaction solution, 2.30 g of ammonium sodium persulfate and 0.12 g
of L-ascorbic acid were added to the reaction solution. As a
result, the polymerization was started in one minute. Then, the
polymerization was performed in one minute, and the polymerization
reaction were performed at 30.degree. C.-50.degree. C., and the
resulting water-containing gel-like polymer was taken out when 60
minutes elapsed after the polymerization started.
The resulting water-containing gel like polymer was finely divided
into around 5 mm. The resulting finely divided water-containing
gel-like polymer was placed on a wire netting of 50 mesh and dried
under hot air at 150.degree. C. for 90 minutes. Then, the resulting
dried polymer was pulverized by a vibrating mill and further
classified by a wire netting of 20 mesh. As a result, a precursor
of the absorbing agent of undefined shape, an average particle
diameter of 360 .mu.m and ratio of particles having a diameter of
106 .mu.m or below of 5 percent by weight was obtained.
To 100 parts by weight of precursor of the absorbing agent, a
surface crosslinking agent composed of 1 part by weight of glycerol
(SP value: .delta.=16.5 (cal/cm.sup.3).sup.1/2) as the first
surface crosslinking agent and 0.05 parts by weight of ethylene
glycol diglycidyl ether (SP value:.delta.=10.2
(cal/cm.sup.3).sup.1/2) as the second surface crosslinking agent, 3
parts by weight of water and 1 part by weight of ethyl alcohol were
mixed. By applying a heat treatment to the resulting mixture for 40
minutes at 195.degree. C., an absorbing agent was obtained. The
resulting absorbing agent has an average particle diameter of 360
.mu.m, and the ratio of the particles with a particle diameter of
less than 106 .mu.m was 5 percent by weight. The results of the
water absorbing agent by the centrifugal separation method and the
diffusing absorbency under pressure (hereinafter simply referred to
as results) of the water absorbing agent are shown in Table 5.
EXAMPLE 17
To 5500 g per weight of 39 percent by weight of sodium acrylate
(neutralization rate 75 percent), was dissolved 3.59 g of
trimethylolpropane triacrylate as a crosslinking agent to prepare a
reaction solution. Next, a deairing operation of the reaction
solution was performed for 30 minutes under an atmosphere of
nitrogen. Next, to the same reaction vessel as the reaction vessel
of the Example 16, the reaction solution was supplied, and the
reaction system was displaced by introducing nitrogen gas while
maintaining the reaction solution at 30.degree. C. Then, while
agitating the reaction solution, 2.40 g of ammonium persulfate and
0.12 g of L-ascorbic acid were added to the reaction solution so as
to start the polymerization, and a polymerization started after
about 1 minute. The polymerization reaction was performed at
30.degree. C.-80.degree. C., and after leaving it for 60 minutes, a
resulting finely divided water-containing gel-like polymer with a
diameter of 5 mm was taken out.
The resulting finely divided water-containing gel-like polymer was
placed on a wire netting of 50 mesh and dried under hot air at
150.degree. C. for 90 minutes. Then, the resulting dried polymer
was pulverized by a vibrating mill and further classified by a wire
netting of 20 mesh. As a result, a precursor of the absorbing agent
of undefined shape, an average particle diameter of 400 .mu.m and
ratio of particles having a diameter of 106 .mu.m or below of 3
percent by weight was obtained.
To 100 parts by weight of the precursor of the absorbing agent, a
surface crosslinking agent composed of 0.5 parts by weight of
ethylene glycol (SP value: .delta.=14.6 (cal/cm.sup.3).sup.1/2) as
the first surface crosslinking agent and 0.1 parts by weight of
glycerol polyglycidyl ether (SP value: .delta.=10.8
(cal/cm.sup.3).sup.1/2), 3 parts by weight of water and 1 part by
weight of ethyl alcohol were mixed. By applying a heat treatment to
the resulting mixture for 40 minutes at 195.degree. C., an
absorbing agent was obtained. The resulting absorbing agent has an
average particle diameter of 400 .mu.m, and the ratio of the
particles with a particle diameter of less than 106 .mu.m was 3
percent by weight. The results of the water absorbing agent are
shown in Table 5.
EXAMPLE 18
To 5500 g of 20 percent by weight of sodium acrylate, 2.35 g of
N,N'-methylenebisacrylamide as a crosslinking agent was dissolved
to prepare a reaction solution, Next, a deairing operation of the
reaction solution was performed for 30 minutes under an atmosphere
of nitrogen. Next, to the same reaction vessel as the reaction
vessel of Example 16, the reaction solution was supplied, and the
reaction system was displaced by introducing nitrogen gas while
maintaining the reaction solution at 30.degree. C. Then, while
agitating the reaction solution maintained at 30.degree. C., 1.5 g
of ammonium persulfate and 0.07 g of L-ascorbic acid were added to
the reaction solution. As a result, a polymerization started in
about one minute. During the polymerization process, temperature
was maintained in a range of 30.degree. C.-80.degree. C. After
leaving it for 60 minutes, 606.7 of sodium carbonate (neutralizing
agent) was further added, and the mixture was stirred. Then, a
resulting water-containing gel-like polymer with a neutralization
ratio of 75 mole percent was taken out.
The resulting water-containing gel-like polymer was finely divided
into around 5 mm. The resulting finely divided water-containing
gel-like polymer was placed on a wire netting of 50 mesh and dried
under hot air at 150.degree. C. for 90 minutes. Then, the resulting
dried polymer was pulverized by a vibrating mill and further
classified by a wire netting of 20 mesh. As a result, a precursor
of the absorbing agent of undefined shape, an average particle
diameter of 390 .mu.m and ratio of particles having a diameter of
106 .mu.m or below of 4 percent by weight was obtained.
To 100 parts by weight of the precursor of the absorbing agent, a
surface crosslinking agent composed of 0.75 parts by weight of
propylene glycol (SP value: .delta.=12.6 (cal/cm.sup.3).sup.1/2) as
the first surface crosslinking agent and 0.05 parts by weight of
propylene glycol diglycidyl ether (SP value: 67 =10.1
(cal/cm.sup.3).sup.1/2) as the second surface crosslinking agent, 3
parts by weight of water and 0.75 part by weight of ethyl alcohol
was mixed. By applying a heat treatment to the resulting mixture
for 40 minutes at 195.degree. C., an absorbing agent was obtained.
The resulting absorbing agent has an average particle diameter of
390 .mu.m, and the ratio of the particles with a particle diameter
of less than 106 .mu.m was 3 percent by weight. The results of the
water absorbing agent are shown in Table 5.
Comparative Example 18
To 5500 g of 39 percent by weight of sodium acrylate
(neutralization rate 75 percent), was dissolved 7.18 g of
trimethylolpropane triacrylate as a crosslinking agent to prepare a
reaction solution. Next, a deairing operation of the reaction
solution was performed for 30 minutes under an atmosphere of
nitrogen. Next, to the same reaction vessel as the reaction vessel
of Example 16, the reaction solution was supplied, and the reaction
system was displaced by introducing nitrogen gas while maintaining
the reaction solution at 30.degree. C. Then, while agitating the
reaction solution maintained at 30.degree. C., 5.0 g of sodium
persulfate and 0.25 g of L-ascorbic acid were added to the reaction
solution. As a result, a polymerization is started in about one
minute. During the polymerization process, temperature is
maintained in a range of 30.degree. C.-80.degree. C. After leaving
it for 60 minutes, the resulting water-containing gel-like polymer
was taken out.
The resulting water-containing gel-like polymer was finely divided
into around 5 mm. The resulting finely divided water-containing
gel-like polymer was placed on a wire netting of 50 mesh and dried
under hot air at 150.degree. C. for 90 minutes. Then, the resulting
dried polymer was pulverized by a vibrating mill and further
classified by a wire netting of 20 mesh. As a result, a comparative
absorbing agent of undefined shape, an average particle diameter of
360 .mu.m and ratio of particles having a diameter of 106 .mu.m or
below of 5 percent by weight was obtained. The results of the
resulting comparative absorbing agent are shown in Table 5.
Comparative Example 19
The same reaction as comparative example 18 was performed in the
same manner except that 18.67 g of N,N'-methylene bisacrylamide was
used as a crosslinking agent in place of trimethylolpropane
triacrylate used in Example 18. As a result, a comparative
absorbing agent of undefined shape with an average particle
diameter of 400 .mu.m and a ratio of particles having a particle
diameter of less than 106 .mu.m of 3 percent by weight was
obtained. The results of the resulting comparative absorbing agent
are shown in Table 5.
Comparative Example 20
A partially neutralized and crosslinked acrylate polymer (aquaric
CA. W4; Nippon Shokubai Co., Ltd.) was used as a comparative
absorbing agent. The results of this comparative example are shown
in Table 5.
Comparative Example 21
A partially neutralized and crosslinked starch-acrylate graft
polymer (Sunwet IM3900P; Hoechst Celanese Co., Ltd.) was used as a
comparative absorbing agent. The results of this comparative
example are shown in Table 5.
Comparative Example 22
A partially neutralized and crosslinked acrylate polymer (Daiyawet
US2-45Z; available from Mitsubishi Petrochemical Co., Ltd.) was
used as a comparative absorbing agent. The results are shown in
Table 5.
Comparative Example 23
A partially neutralized and crosslinked acrylate polymer (Aquakeep
SA-60; available from Sumitomo Seika Co., Ltd.) was used as a
comparative absorbing agent. The results are shown in Table 5.
Comparative Example 24
An absorbent resin was taken out from a paper diaper (Mammy poco
available from Unicharm Co., Ltd.) and used as a comparative
absorbing agent. The results of this comparative example are shown
in Table 5.
TABLE 5 Absorbency by Diffusing absorbency under centrifuge
pressure (g/g) separation after 20 after 30 after 60 method minutes
minutes minutes Example 16 31 20.8 28.6 31.3 Example 17 30 22.5
27.9 30.1 Example 18 38 16.0 24.0 33.9 Comp. 31 3.6 5.9 11.7
Example 18 Comp. 18 10.1 16.7 21.1 Example 19 Comp. 40 20.3 22.1
23.1 Example 20 Comp. 33 4.2 6.5 11.7 Example 21 Comp. 37 6.9 9.7
12.2 Example 22 Comp. 39 9.6 13.9 21.1 Example 23 Comp. 32 3.7 5.7
9.1 Example 24
EXAMPLE 19
45 parts by weight of the absorbing agent obtained from Example 16
and 55 parts by weight of groundwood pulp were mixed by a mixer
using a dry method. The resulting mixture was formed into a web
with a size of 100 mm.times.100 mm. Thereafter, by pressing the web
for 1 minute with a pressure of 2 kg/cm.sup.2, an absorbent product
composed of an absorbent material with a basis weight of around
0.050 kg/cm.sup.2 was obtained. The results of the diffusing
absorbency under pressure of the absorbent material (hereinafter
simply referred to as unit) are shown in Table 6.
EXAMPLE 20
50 parts by weight of absorbing agent obtained from Example 16 and
50 parts by weight of groundwood pulp were mixed by a mixer using a
dry method. The resulting mixture was formed into a web with a size
of 100 mm.times.100 mm. Thereafter, by pressing the web for one
minute with a pressure of 2 kg/cm.sup.2, an absorbent material with
a basis weight of around 0.047 kg/cm.sup.2 was obtained. The
results of the absorbent material (hereinafter simply referred to
as unit) are shown in Table 6.
EXAMPLE 21
60 parts by weight of the absorbing agent obtained from Example 16
and 40 parts by weight of groundwood pulp were mixed by a mixer
using a dry method. The resulting mixture was formed into a web
with a size of 100 mm.times.100 mm. Thereafter, by pressing the web
for 1 minute under pressure of 2 kg/cm.sup.2, an absorbent material
with a basis weight of around 0.041 kg/cm.sup.2 was obtained. The
results of the absorbent material (hereinafter simply referred to
as unit) are shown in Table 6.
EXAMPLE 22
75 parts by weight of the absorbing agent obtained from Example 16
and 25 parts by weight of groundwood pulp were mixed by a mixer
using a dry method. The resulting mixture was formed into a web
with a size of 100 mm.times.100 mm. Thereafter, by pressing the web
for 1 minute with a pressure of 2 kg/cm.sup.2, an absorbent
material with a basis weight of around 0.035 kg/cm.sup.2 was
obtained. The results of the absorbent material are shown in Table
6.
EXAMPLES 23 AND 24
The same operation as Example 22 was performed in the same manner
except that absorbing agents obtained from Examples 17 and 18 were
used in place of the absorbing agent obtained from Example 16. The
results of the absorbent material are shown in Table 6.
Comparative Example 25
The same operation as Example 19 was performed except that the
comparative absorbing agent obtained from Comparative Example 18
was used in place of the absorbing agent obtained from Example 16.
The results of the comparative absorbent material are shown in
Table 6.
Comparative Example 26
The same operation as Example 20 was performed except that the
comparative absorbing agent obtained from Comparative Example 18
was used in place of the absorbing agent obtained from Example 16.
The results of the comparative absorbent material are shown in
Table 6.
Comparative Example 27
The same operation as Example 21 was performed except that
comparative absorbing agent obtained from Comparative Example 18
was used in place of the absorbing agent obtained from Example 16.
The results of the comparative absorbent material are shown in
Table 6.
Comparative Examples 28-34
The same operation as Example 22 was performed in the same manner
except that comparative absorbing agents obtained from Comparative
Examples 18-24 were used in place of the absorbing agent obtained
from Example 16. The results of the comparative absorbent material
are shown in Table 6.
TABLE 6 Diffusing absorbency under pressure of Absorbent material
(g/g) after 30 min. after 60 min. Example 19 19.4 19.7 Example 20
19.5 20.1 Example 21 19.3 22.2 Example 22 19.1 24.3 Example 23 19.4
23.1 Example 24 17.9 25.6 Comparative 17.6 18.5 Example 25
Comparative 10.1 15.1 Example 26 Comparative 9.6 14.2 Example 27
Comparative 7.3 10.4 Example 28 Comparative 13.0 16.9 Example 29
Comparative 16.0 18.3 Example 30 Comparative 7.4 10.7 Example 31
Comparative 9.1 10.7 Example 32 Comparative 11.5 15.8 Example 33
Comparative 6.8 8.6 Example 34
EXAMPLE 25
50 parts by weight of absorbing agent obtained from Example 16 and
50 parts by weight of groundwood pulp were mixed with a mixer using
a dry method. Next, to the resulting mixture, by performing a
pneumatic molding using a batch-type pneumatic molding device on a
wire screen formed with 400 mesh (38 .mu.m), a web with 120
mm.times.400 mm size is formed. By pressing the web with a pressure
of 2 kg/cm.sup.2, for 5 seconds, an absorbent material with a
weighting capacity of around 0.047 kg/cm.sup.2 was obtained.
Thereafter, a so-called back sheet made of polypropylene which is
impermeable to liquid, a back sheet having a leg gather (liquid
impermeable sheet), the absorbent material, the top sheet made of
polypropylene which is permeable to liquid (liquid permeable sheet)
are formed by laminating them using a both-sided tape. By
laminating these sheets using a both-sided tape, and mounting two
tape fasteners on the adhering material, the absorbent product (a
so-called paper diaper) was obtained. The weight of the absorbent
product was 46 g.
The absorbent product was mounted on a so-called Cupy doll (height
55 cm and weight 5 kg), and the doll was placed facing down. Then,
a tube was inserted between the absorbent product and the doll, and
50 ml of physiological saline solution was injected each time into
the portion corresponding to the portion from which urea is to be
discharged at an interval of 20 minutes. Then, when the
physiological saline solution was not absorbed in the absorbent
product and leaking, the described injecting operation was ended,
and the amount of the absorbed physiological saline solution was
measured.
After repeating the measurements four times, the average of the
measurement was calculated, and the resulting value was determined
as an absorbing amount. As a result, the absorbing amount of 250 g
was obtained.
Comparative Example 35
The same reaction as Example 25 was performed in the same manner
except that the comparative absorbing agent resulting from
comparative example 18 was used in place of the absorbing agent
from Example 16. The weight of the comparative absorbent product
was 46 g.
Using the comparative absorbent product, the same operation as
Example 25 was repeated four times, and thereafter, the average of
the resulting measurement value was calculated, and the value was
determined as an absorbing amount. As a result, the absorbing
amount of 255 g was obtained.
As is clear from the results described in Table 5 and Table 6, the
absorbing agent and the absorbent material of the present invention
has high diffusing absorbency under pressure and very high
diffusivity to liquid. The difference in absorbent properties of
the absorbing agent and the absorbent material between the present
invention and comparative examples becomes greater as the resin
concentration of the absorbent material becomes greater. As is
clear from the results described in Example 25 and comparative
Example 35, the absorbent property of the absorbent product of the
present invention shows excellent properties (absorbent properties)
such as very high absorbing amount (absorbing capacity) as compared
to the comparative absorbent product.
The invention being thus described, it will be obvious that the
same may be varied in many ways. Such variations are not to be
regarded as a departure from the spirit and scope of the invention,
and all such modifications as would be obvious to one skilled in
the art are intended to be included within the scope of the
following claims.
[Possible Industrial Applications]
The absorbing agent and the absorbent material are suitably applied
essentially to thinner absorbent products such as a paper diaper, a
sanitary napkin of higher performances, etc. As a result, the
present invention provides absorbent products having excellent
performances.
* * * * *